John Deere 4990 Self-Propelled Windrower Repair Technical Manual TM1819 19OCT01

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