John Deere Self-Propelled Hay and Forage Windrower 4990 Repair Service Manual (TM1819)

TM1819 - John Deere Self-Propelled Hay and Forage Windrower 4990 Technical Manual (Repair).PDF

Complete service repair manual for John Deere Self-Propelled Hay and Forage Windrowers Models 4990, with all the service information to maintain, repair, rebuild like professional mechanics.

John Deere 4990 Self-Propelled Hay and Forage Windrower workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,293 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   John Deere Dealers
   Service Technician Response
   General
      Safety
      Specifications
      Fuel, Coolant and Lubricants
   Engine
      Engine
      Cooling System
   Fuel and Air Systems
      Air Intake and Exhaust
      Diesel Fuel System
   Electrical
      Batteries
      Starter
      Alternator
      Engine Electrical Components
      Lighting and Accessory Components
      Gauges and Monitors
      Platform and Ground Speed Controls
      Cab Heat and A/C Electrical Components
      Connector Repair
   Power Train
      Hydrostatic System Flushing and Start-Up
      Pump Drive Gear Case
      Circulating Pump and Oil Cooler
      Ground Drive Pumps
      Ground Drive Motor
      Final Drive (S.N. -163100)
      Final Drive (S.N. 163101-)
      Ground Drive Linkage (S.N. -163100)
      Ground Drive Linkage (S.N. 163101-)
   Steering and Brakes
      Steering System (S.N. -163100)
      Steering System (S.N. 163101-)
      Brakes
   Hydraulic System
      Auxiliary-Charge Pump
      Platform Drive Pump
      Platform Drive Motor
      Main Hydraulic Control Valve
      Hydraulic Cylinders
      Miscellaneous
   Miscellaneous
      Rear Axle
      Drive Wheels
      Lift Arm
   Operator Station
      Air Conditioning Service
      Air Conditioning Repair
      Heater Controls
      Cab (S.N. -163100)
      Cab (S.N. 163101- )
   Dealer Fabricated Tools

tm1819 - 4990 self-propelled windrower

Table of Contents

Foreword

John Deere Dealers

Service Technician Response

Section 10: General

Group 05: 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

Group 10: 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

Group 15: 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

Section 20: Engine

Group 05: 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

Group 10: 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

Section 30: Fuel and Air Systems

Group 05: 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

Group 10: 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

Section 40: Electrical

Group 05: Batteries

Specifications

Remove and Install Battery(ies)

Using Booster Batteries-12 Volt System

Charging Battery(ies)

Checking Specific Gravity

Group 10: Starter

Starter Repair-Use CTM77

Specifications

Remove and Install Starter Motor

Group 15: Alternator

Alternator Repair-Use CTM77

Remove and Install Alternator

Group 20: 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

Group 25: 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

Group 30: Gauges and Monitors

Replace Warning Panel or Light Bulbs

Replace Gauges or Gauge Light Bulbs

Replace Tachometer

Program Tachometer

Group 35: 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

Group 40: 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

Group 45: 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 METRIMATE is a trademark of AMP Inc. Pin Type Connectors

Replace DEUTSCH Connectors

Install DEUTSCH Terminals

Section 50: Power Train

Group 05: 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

Group 10: 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

Group 15: Circulating Pump and Oil Cooler

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 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

Group 20: 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 Left-Hand Ground Drive Pump

Remove and Install Right-Hand Ground Drive Pump

Disassemble Ground Drive Pump

Inspect Ground Drive Pump

Assemble Ground Drive Pump

Group 25: Ground Drive Motor

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 Ground Drive Motor

Disassemble Ground Drive Motor

Inspect Ground Drive Motor

Assemble Ground Drive Motor

Group 30: 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

Group 31: 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

Group 35: Ground Drive Linkage (S.N. -163100)

Remove and Install Ground Drive Control Cables

Remove and Install Ground Drive Linkage Rods

Group 36: Ground Drive Linkage (S.N. 163101-)

Remove and Install Ground Drive Control Cable

Remove and Install Ground Drive Linkage Rods

Section 60: Steering and Brakes

Group 05: 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

Group 06: 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

Group 10: Brakes

Service Equipment and Tools

Specifications

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

Remove and Install Brake Disk and Caliper

Disassemble Brake Disk and Caliper

Inspect Brake Disk and Caliper Components

Assemble Brake Disk and Caliper

Section 70: Hydraulic System

Group 05: Auxiliary-Charge Pump

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 Auxiliary-Charge Pump

Disassemble Auxiliary-Charge Pump

Inspect Auxiliary-Charge Pump

Assemble Auxiliary-Charge Pump

Group 10: 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-)

Remove and Install Platform Drive Pump

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

Group 15: Platform Drive Motor

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 Platform Drive Motor

Disassemble Platform Drive Motor

Inspect Platform Drive Motor

Assemble Platform Drive Motor

Group 20: Main Hydraulic Control Valve

Essential or Recommended Tools

Specifications

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

Remove and Install Main Hydraulic Control Valve

Disassemble and Assemble Main Hydraulic Control Valve

Replace Solenoid Coils and Valve Cartridges

Group 25: Hydraulic Cylinders

Service Equipment and Tools

Other Material

Specifications

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

Group 30: 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

Section 80: Miscellaneous

Group 05: 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

Group 10: Drive Wheels

Specifications

Remove and Install Drive Wheels

Group 15: Lift Arm

Service Equipment and Tools

Specifications

Replace Lift Arm Bearings

Section 90: Operator Station

Group 05: 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

Group 10: 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

Group 15: Heater Controls

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

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

Group 20: 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

Check Hydrostatic Ground Drive

Adjust Hydrostatic Ground Drive

Group 21: 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 AirSuspension Assembly

Assemble Operator's Seat Air Suspension Assembly

Replace Cab Mount Isolators

Check Hydrostatic Ground Drive

Adjust Hydrostatic Ground Drive

Section 99: Dealer Fabricated Tools

Group 05: 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