john deere 4440 tractor service manual · john deere model: 4440 chassis only volume 1 of 3 this is...

John Deere

MODEL:

4440 Chassis Only Volume 1 of 3

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

JD-S-TM1182

http://www.jensales.com/products/john-deere-4440-tractor-service-manual.html

4440 Tractor

TECHNICAL MANUAL 4440

Tractor

TM1182 (01 SEP77) English

TM1182 (01 SEP77)


1

4440 TRACTOR TECHNICAL MANUAL

TM-1182 (SEP-77) CONTENTS-REPAIR SECTIONS

SECTION 1o-GENERAL Group Oo-Specifications and Special Tools Group 05-Predelivery, Delivery, and After-Sale

Services Group 1o-Tune-Up Group 15-Lubrication Group 2o-Separation

SECTION 2o-ENGINE REPAIR Group Oo-Specifications and Special Tools Group 05-Cylinder Head, Valves, and Camshaft Group 1o-Cylinder Block, Liners, Pistons, and

Rods Group 15-Crankshaft, Main Bearings, and

Flywheel Group 2o-Lubricating System Group 25-Cooling System

SECTION 3O-FUEL AND AIR REPAIR Group Oo-Specifications and Special Tools Group 05-Air Intake System Group 1o-Diesel Fuel System Group 15-Control Linkage

SECTION 4o-ELECTRICAL REPAIR Group Oo-Specifications and Special Tools Group 05-Harness Replacement Group 1o-Charging Circuit Group 15-Starting Circuit Group 2o-Lighting Circuits Group 25-lnstrument and Accessory Circuits Group 3O-Power Front-Wheel Drive

SECTION 50-POWER TRAIN REPAIR Group Oo-Specifications and Special Tools Group 05-Perma-Clutch@> Group 1o-0uad-Range@> Planetary Group 15-0uad-Range Transmission Group 2o-Power Shift Transmission Group 25-Power Take-Off Group 3O-Differential Group 35-Final Drive Group 4o-Power Front-Wheel Drive

SECTION SO-STEERING/BRAKES REPAIR Group OO-Specifications and Special Tools Group 05-Power Steering Group 1o-Power Brakes

SECTION 7o-HYDRAULIC REPAIR Group Oo-Specifications and Special Tools Group 05-Miscellaneous Hydraulic Components Group 1 o-Hydraulic Pumps Group 15-Rockshaft and Implement Hitches Group 2o-Selective Control Valve, and Remote

Cylinder

SECTION ao-MISCELLANEOUS Group Oo-Specifications and Special Tools Group 05-Front Axles Group 1o-Wheels

SECTION gO-OPERATOR STATION REPAIR Group Oo-Specifications and Special Tools Group 05-Air Conditioning System Group 1o-Heating System Group 15-Seat Group 2o-Miscellaneous Components

(Continued on page 2)

All 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-1182 (Sep-77) Litho in U.S.A. Tractor - 4440


2

CONTENTS-OPERATION AND TESTS SECTIONS

SECTION 22,O-ENGINE OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-System Operation Group 10-System Tests and Diagnosis

SECTION 230-FUEL/AIR OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-Air Intake System Group 10-Diesel Fuel System Group 15-Control Linkage

SECTION 240-ELECTRICAL OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-General Information and Diagrams Group 10-Charging Circuit Group 15-Starting Circuit Group 20-Lighting Circuits Group 25-lnstrument and Accessory Circuits Group 30-Power Front-Wheel Drive Group 35-Electrical Remote Control and Outlet

Socket

SECTION 250-POWER TRAIN OPERATION AND TESTS

Group ~O-Specifications and Special Tools Group 05-Quad-Range System Operation Group 10-Quad-Range Tests and Diagnosis Group 15-Power Shift System Operation Group 20-Power Shift Tests and Diagnosis Group 25-Differential and Final Drive Group 30-Power Front-Wheel Drive

TM-1182 (Sep-77) Litho in U.S.A.

SECTION 260-STEERING/BRAKES OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-Power Steering Group 10-Power Brakes

SECTION 270-HYDRAULIC OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-Hydraulic System Operation Group 10-Hydraulic System Tests Group 15-Miscellaneous Hydraulic Components Group 20-Hydraulic Pumps Group 25-Rockshaft and Implement Hitches Group 30-Selective Control Valve and Remote

Cylinder

SECTION 290-0PERATOR STATION OPERATION AND TESTS

Group OO-Specifications and Special Tools Group 05-Air Conditioning System Group 10-Heating System

Tractor - 4440


General Specifications and Special Tools 10-00-1

Section 10 GENERAL

CONTENTS OF THIS SECTION Page

GROUP OO-SPECIFICATIONS General Tractor Specifications . . . . . . . . .. 10-00-1 Predelivery .. . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-4 Tune-Up ............................. 10-00-5 Lubrication .......................... " 10-00-5 Separation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . .. 10-00-7

GROUP 05-PREDELIVERY, DELIVERY, AND AFTER-SALE SERVICES

Dealer Predelivery Service ........... " 10-05-1 Inspection Checks. . . . . . . . . . . . . . . . . . .. 10-05-11 Dealer Service . . . . . . . . . . . . . . . . . . . . . .. 10-05-13 After Sale Inspection ................. 10-05-14

GROUP 10-TUNE-UP Preliminary Engine Testing. . . . . . . . . . . .. 10-10-1 Engine Tune-Up ...................... 10-10-1 Operation ........................... " 10-10-7 General .............................. 10-10-7

Page GROUP 15-LUBRICATION

Lubricants .......................... " 10-15-1 Engine ............................... 10-15-2 Transm iss ion-Hydraulic System ........ , 10-15-3 Hi-Crop Final Drive Housings. . . . . . . . . .. 10-15-5 Front Wheel Bearings. . . . . . . . . . . . . . . . .. 10-15-6 Grease Fittings. . . . . . . . . . . . . . . . . . . . . . .. 10-15-6

GROUP 20-SEPARATION Removing Sound-Gard® Body without

Control Support. . . . . . . . . . . . . . . . . . . .. 10-20-1 Removing Sound-Gard Body with

Control Support. . . . . . . . . . . . . . . . . . . .. 10-20-5 Separating Engine from

Clutch Housing .................... 10-20-10 I Removing Front End. . . . . . . . . . . . . . . . .. 10-20-14 Removing Engine ............ " ...... 10-20-18 Separating Clutch Housing from

Power Shift Transmission Case ...... 10-20-21 Separating Clutch Housing from

Quad-Range Transmission Case .... 10-20-24 Removing Rear Axle Housing ......... 10-20-26

Group 00 SPECIFICATIONS AND AND SPECIAL TOOLS

GENERAL TRACTOR SPECIFICATIONS HORSEPOWER (Factory observed PTO

horsepower at 2200 rpm)

ENGINE: Type Slow idle speed Working speed range Bore and stroke Displacement Compression ratio Firing order Valve clearance

Intake Exhaust

Injection pump timing Lubrication system

TM-1182 (Jun-80) Litho in U.S.A.

130 hp (97 kW)

6-cylinder, in-line, valve-in head, diesel, turbocharged, 800 rpm 1500 to 2200 rpm 4.56 x 4.75 in. (116 x 121 mm) 466 cu. in. (7.6 L) 14.9 to 1 1-5-3-6-2-4

0.018 in. (0.46 mm) 0.028 in. (0.71 mm) TDC force-feed, pressurized with full-flow filter

Tractor - 4440


General Separation 10-20-1

Group 20 SEPARATION

REMOVING SOUND-GARD BODY WITHOUT CONTROL SUPPORT

R

Fig. 1-Removing Sound-Gard Body Without Control Support

NOTE: Either the Brown Body Lift (shown) or a fork lift with Fork Lift Adapters (see special tools) 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 control 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 air intake stack. S. Remove left- and right-hand grille screens.

Tractor - 4440


Engine Repair Specifications and Special Tools 20-00-1

Section 20 ENGINE REPAIR

CONTENTS OF THIS SECTION

Group 00 - SPECIFICATIONS AND SPECIAL TOOLS

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 20-00-2 Special Tools ......................... 20-00-4

GROUP 05 - CYLINDER HEAD, VALVES AND CAMSHAFT

Preliminary Valve Checks . . . . . . . . . . . . .. 20-05-1 Checking Valve Clearance ............. 20-05-1 Checking Valve Lift. . . . . . . . . . . . . . . . . . .. 20-05-2 Cylinder Head and Valves .............. 20-05-3

Access ........................... " 20-05-3 Rocker Arm Assembly . . . . . . . . . . . . . . . .. 20-05-3

Removal ........................... 20-05-3 Inspection and Repair . . . . . . . . . . . . . .. 20-05-3 Assembly and Installation .......... " 20-05-4

Valves, Valve Springs, Valve Rotators, and Wear Caps . . . . . . . . . . . . . . . . . . . .. 20-05-4 Removal .......................... , 20-05-4 Inspection and Repair . . . . . . . . . . . . . .. 20-05-4

Valve Springs .................... 20-05-4 Valves, Rotators and Wear Caps. .. 20-05-4 Valve Guides. . . . . . . . . . . . . . . . . . . .. 20-05-5 Valve Seats . . . . . . . . . . . . . . . . . . . . .. 20-05-6

Cylinder Head ........................ 20-05-8 Assembly .......................... 20-05-8 Installation .......................... 20-05-8

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-9 Checking Camshaft End Play ........ 20-05-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-05-9 Inspection and Repair . . . . . . . . . . . . .. 20-05-10

Camshaft Gear . . . . . . . . . . . . . . . . .. 20-05-10 Thrust Plate . . . . . . . . . . . . . . . . . . . .. 20-05-10 Bushings and Journals . . . . . . . . . .. 20-05-10 Lobes .......................... 20-05-11

Assembly ......................... 20-05-11 Installation ......................... 20-05-11

GROUP 10 - CYLINDER BLOCK, LINERS, PISTONS AND RODS

Diagnosing Malfunctions ............... 20-10-1 Pistons .............................. , 20-10-1

Access . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 20-1 0-1 Removal ............... . . . . . . . . . . .. 20-10-2 Inspection and Repair .............. , 20-10-2

Piston Rings and Ring Grooves .... 20-10-2 Piston Head, Ring Lands and Piston

Skirt .......................... , 20-10-3 Piston Pins ...................... , 20-10-4

TM-1182 (Apr-8t) Litho in U.S.A.

Connecting Rods. . . . . . . . . . . . . . . . . . . . .. 20-10-4 Removal .. . . . . . . . . . . . . . . . . . . . . . . . .. 20-10-4 Inspection and Repair . . . . . . . . . . . . . .. 20-10-4

Connecting Rod Bearings. . . . . . . . .. 20-10-5 Cylinder Liners

Removal, Inspection, and Repair ..... 20-10-5 Deglazing Cylinder Liners. . . . . . . . .. 20-10-7

Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-1 0-7 Inspection and Repair. . . . . . . . . . . .. 20-10-7 Installation ...................... , 20-10-8 Liners ............................ 20-10-8 Pistons and Connecting Rods . . . . .. 20-10-8

GROUP 15 - CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL

Diagnosing Malfunctions .. : . . . . . . . . . . .. 20-15-1 Access .............................. , 20-15-1 Inspection and Repair ................. 20-15-1

Damper Pulley ...................... 20-15-1 Front Wear Sleeve . . . . . . . . . . . . . . . . .. 20-15-2 Crankshaft Gear . . . . . . . . . . . . . . . . . . .. 20-15-2 Flywheel .. . . . . . . . . . . . . . . . . . . . . . . . .. 20-15-2 Clutch Shaft Pilot Bearing (Power Shift) 20-15-3 Clutch Shaft Pilot Bushing and Adapter

(QUAD-RANGE) .................. 20-15-3 Rear Crankshaft Oil Seal, Housing and

Wear Sleeve . . . . . . . . . . . . . . . . . . . .. 20-15-4 Main Bearings ...................... 20-15-4 Thrust Bearings. . . . . . . . . . . . . . . . . . . .. 20-15-5 Crankshaft Journals . . . . . . . . . . . . . . . .. 20-15-6

Installation ............................ 20-15-6 Main Bearings and Crankshaft ...... :. 20-15-6 Rear Wear Sleeve ......... . . . . . . . .. 20-15-7 Rear Oil Seal and Housing. . . . . . . . . .. 20-15-7 Crankshaft Gear, Front Wear Sleeve

and Oil Seal. . . . . . . . . . . . . . . . . . . . .. 20-15-8

GROUP 20 - LUBRICATION SYSTEM Diagnosing Malfunctions ............... 20-20-1 Removal, Inspection and Repair ........ 20-20-1

Oil Filter Housing ................... 20-20-1 Oil Cooler .......................... 20-20-1 Oil Pumps. . . . . . . . . . . . . . . . . . . . . . . . .. 20-20-2 Tachometer Drive ................. " 20-20-5

Assembly and Installation ............ " 20-20-6 Oil Cooler By-Pass Valve. . . . . . . . . . .. 20-20-6 Oil Pumps ............. '.' . . . . . . . . . .. 20-20-6 Tachometer Drive ................... 20-20-9

Tractor - 4440


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

SPECIFICATIONS Item New Part Specification

Cylinder Head, Valves, and Camshaft

Valve clearance Intake vaive .......................... 0.018 in. (0.46 mm) Exhaust valve ......................... 0.028 in. (0.71 mm)

Valve lift at specified clearance Intake valve .......................... 0.412 to 0.442 in. (10.46 to 11.23 mm) Exhaust valve ......................... 0.413 to 0.443 in. (10.49 to 11.25mm)

Valve springs - compressed Valve closed .......................... 1.81 in. at 54 to 62 Ibs.

(45.9 mm at 240.2 to 275.8 N) Valve open . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.36 in. at 133 to 153 Ibs.

(35.5 mm at 591.6 to 680.5 N) Valve face angle ......................... 300

Valve face 0.0 .......................... 1.710 to 1.720 in. (43.4 to 43.7 mm) Valve guide 1.0 .......................... 0.3745 to 0.3755 in. (9.51 to 9.54 mm) Valve stem 0.0 .......................... 0.3715 to 0.3725 in. (9.44 to 9.46 mm)

Wear Tolerance

Valve stem-to-guide clearance ............ 0.0020 to 0.0040 in. (0.05 to 0.10 mm) ............ " 0.0060 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 ........................ 300

Valve face above head ................... 0.0240 to 0.0380 in. (0.62 to 0.96 mm) .... 0.0060 in. (1.52 mm) recessed

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. (4.72 to 4.80 mm) .... 0.1820 in. (4.62 mm) Camshaft bushing journal 0.0 ............. 2.3745 to 2.3755 in. (60.31 to 60.34 mm) Camshaft bushing 1.0 .................... 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) (2.7 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 In new cylinder block .................. 0.001 to 0.005 in. (0.03 to 0.12 mm) In used cylinder block ................. 0.000 to 0.004 in. (0.00 to 0.10 mm)

Piston oil control ring side clearance ...... 0.002 to 0.004 in. (0.06 to 0.10 mm) ......... 0.006 in. (0.1 mm)

TM-11B2 (Apr-B1) Litho in U.S.A. Tractor - 4440


Fuel and Air Repair Specifications and Special Tools 30-00-1

Section 30 FUEL AND AIR REPAIR


GROUP 00 - SPECIFICATIONS AND SPECIAL TOOLS

Specifications

Page

Air Intake System . . . . . . . . . . . . . . . . . . . . .. 00-2 Diesel Fuel System .................... 00-3 Control Linkage ....................... , 00-3

Special Tools ............................ 00-4

GROUP 05 - AIR INTAKE SYSTEM Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-1 AiResearch T -04B Turbo-

charger .............................. , 05-3 Schwitzer 3LM Turbo-

charger ...... . . . . . . . . . . . . . . . . . . . . . . .. 05-11 Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . .. 05-18 Ether Starting Aid ....................... 05-19


Page

GROUP 10 - DIESEL FUEL SYSTEM Fuel Tank ............................... 10-1 Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . .. 10-3 Fuel Check Valve ............... . . . . . . . .. 10-3 Fuel Filter .............................. , 10-4 Bleeding Fuel System .................... 10-6 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . .. 10-6 Aneroid ................................ 1 0-11 Hydraulic Aneroid Activator. .. . . . . . . . . . . .. 10-12 I njection Nozzles ......... , ............ " 10-13

GROUP 15 - CONTROL LINKAGE Speed Control Linkage ................... , 15-1 Foot Throttle Linkage . . . . . . . . . . . . . . . . . . . .. 15-3

Tractor - 4440


Electrical Repair Specifications and Special Tools 40-00-1

Section 40 ELECTRICAL REPAIR


Page

GROUP OO-SPECIFICATIONS AND SPECIAL TOOLS

General Information ................... 40-00-2 Charging Circuit ....................... 40-00-3 Starting Circuit ........................ 40-00-3 Lighting Circuits ....................... 40-00-4 Instrument and Accessory Circuits ...... 40-00-4 Power Front-Wheel Drive .............. 40-00-5 Special Tools ......................... 40-00-6

GROUP 05-HARNESS REPLACEMENT General Information ................... 40-05-1 Right-Hand Lighting Harness

(ROLL-GAR D) ...................... 40-05-1 Right-Hand Lighting Harness

(SOUND-GAR D) .................... 40-05-4 SOUND-GARD Body Harness .......... 40-05-4 Removing Connector Body. . . . . . . . . . . .. 40-05-5

GROUP 10-CHARGING CIRCUIT Removal ............................. 40-10-1 Disassembly .......................... 40-10-1 Repair ............................... 40-10-2 Assembly ............................. 40-10-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-10-6


Page

GROUP 15-STARTING CIRCUIT General Information ................... 40-15-1 Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-15-1 Starting Motor Removal. . . . . . . . . . . . . . .. 40-15-2 Disassembly and Repair ............... 40-15-3 Assembly ............................. 40-15-9 Installation ........................... , 40-15-9

GROUP 20-LlGHTING CIRCUITS Testing Flood Lamp Relays ..... ~ ...... 40-20-1 Testing TUrn Signal Controller ........... 40-20~2 Testing Light Switch ................... 40~20-2 Bulb Replacement. .................... 40-20-3

GROUP 25-INSTRUMENT AND ACCESSORY CIRCUITS

Instrument Cluster .................... , 40-25-1 Radio and Tape Player ................ 40-25-4 Right-Hand Wiper Motor ............... 40-25-5 Left-Hand Wiper Motor ................. 40~25-6

GROUP 30-POWER FRONT-WHEEL DRIVE Power Shift Transmission Switches ..... 40-30-1 QUAD-RANGE Transmission Switches .. 40-30-2

Tractor - 4440


Power Train Repair Specifications and Special Tools 50-00-1

Section 50 POWER TRAIN REPAIR


Group OO-SPECIFICATIONS AND SPECIAL TOOLS

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-3 Special Tools ........................... 00-13

Group 05-PERMA-CLUTCH Pressure Regulating Valve Housing ........ 05-1 Clutch Operating Assembly .............. " 05-3 Clutch Pack ............................. 05-9 Adjustment

Clutch Valve Operating Rod. . . . . . . . . . . .. 05-8 Clutch Pack ......................... , 05-11

GROUP 10-QUAD-RANGE PLANETARY Removal ................................ 1 0-1 Disassembly ........................... " 10-4

Control and Shift Valve. . . . . . . . . . . . . . . .. 10-5 Repair and Assembly

Control and Shift Valve. . . . . . . . . . . . . . . .. 10-6 Brake and Clutch ...................... 10-6 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-8

Group 15-QUAD-RANGE TRANSMISSION Removal

Shifter ................................ 15-1 Transmission Drive Shaft ............... 15-2 Differential Drive Shaft. ............... " 15-3 Counters haft ......................... " 15-3

Transmission Drive Shaft Disassembly and Repair .............. " 15-4 Assembly ............................. 15-5

Countershaft Disassembly and Repair ...... 15-7 Differential Drive Shaft Repair . . . . . . . . . . . .. 15-7 Shaft Installation and Adjustment

Counters haft . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-8 Differential Drive Shaft. . . . . . . . . . . . . . . . .. 15-8 Transmission Drive Shaft and Shifter. . .. 15-11

Range and Speed Selector Assembly Removal ......... . . . . . . . . . . . . . . . . . . .. 15-13 Disassembly and Repair ............... 15-14 Assembly ............................ 15-15 Installation and Adjustment. . . . . . . . . . . .. 15-16

TM-1182 (Oct-78) Litho in U.S.A.

Page Group 20-POWER SHIFT TRANSMISSION

Torsional Damper ........................ 20-1 Clutch Pack

Removal and Disassembly. . . . . . . . . . . . .. 20-2 Transmission Oil Pump ................. 20-4 Assembly and Repair. . . . . . . . . . . . . . . . . .. 20-5

Planetary Brake Pack Removal .... . . . . . . . . . . . . . . . . . . . . . . . . .. 20-9 Disassembly, Repair and Assembly ..... 20-10 Installation ............................ 20-18

Reduction Gear Train, Differential Drive Shaft, Park Pawl and Tow Disconnect

Removal ............. . . . . . . . . . . . . . . .. 20-18 Repair, Assembly and Adjustment ...... 20-21

Pressure Regulating Valve and Pedal Valve ................................ 20-22

Control and Shift Valve .................. 20-25 Speed Selector ......................... 20-27 Adjustments

Oil Pressure Regulating Valve .......... 20-29 Pedal Valve .......................... 20-29 Pedal Height ......................... 20-30 Speed Selector . . . . . . . . . . . . . . . . . . . . . .. 20-30

Group 25-PTO Quad-Range Transmission PTO ........... 25-1 Power Shift Transmission PTO ............ 25-5

Group 30-DIFFERENTIAL Removal

Quad-Range Differential .... . . . . . . . . . . .. 30-1 Power Shift Differential ................. 30-2

Repair .................................. 30-3 Installation and Adjustment. . . . . . . . . . . . . . .. 30-5 Differential Lock Valve

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-6 Dissassembly and Repair . . . . . . . . . . . . . .. 30-7 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-8

Tractor - 4440


50-00-2 Specifications and Special Tools Power Train Repair

CONTENTS OF THIS SECTION-Continued

Page Group 35-FINAL DRIVE

Removal ................................ 35-1 Disassembly and Repair .................. 35-2 Assembly and Adjustment ................. 35-5 Adjusting Axle Bearings. . . . . . . . . . . . . . . . . .. 35-7 Rolling Drag Torque ..................... 35-11 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35-18

Hi-Crop Final Drive Removal ............................. 35-15 Repair and Assembly .................. 35-15 Installation ............................ 35-18

TM-1182 (Oct-78) Litho in U.S.A.

Page Group 4o-POWER FRONT-WHEEL DRIVE

Removal Control Valve. . . . . . . . . . . . . . . . . . . . . . . . .. 40-1 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-2 Wheel Manifold and Motor . . . . . . . . . . . . .. 40-2

Repair Control Valve. . . . . . . . . . . . . . . . . . . . . . . . .. 40-3 Pivot Pin and Bushing ................. , 40-6 Motor Housing. . . . . . . . . . . . . . . . . . . . . . . .. 40-6

Installation and Adjustment Wheel Bearing Adjustment ............. , 40-7 Brake Piston Housing .................. 40-9 Planetary. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-10

Oil Manifold Repair. . . . . . . . . . . . . . . . . . . . . . 40-11 Wheel Motor

Disassembly .......................... 40-11 Repair and Assembly .............. '. . . . 40-12 Adjustments .......................... 40-12

Tractor - 4440


50-40-2 Power Front-Wheel Drive

REMOVAL-Continued

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, splitting 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-First Planetary B-First Sun Pinion

C-Second Sun Pinion

Fig. 4-Removing Outer Planetary

4. Remove outer wheel cover and remove planetary (A, Fig. 4).

5. Remove first sun pinion stub shaft (8) and second 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.

TM-1182 (SeD-77) Litho in U.S.A.

Power Train Repair

Wheel Manifold and Motor Removal ,

A-Relief Valve B-R.H. Steering

Arm

C-Cap Screws D-Oil Manifold

Fig. 5-Wheel Motor Manifold Removal

1. Remove tie rod at steering arm (8, Fig. 5) and turn wheel for manifold removal.

2. Remove relief valve (A) from manifold.

3. Remove manifold cap screws (C) and lift oil manifold (D) off dowel pins.

Trar.tnr - 4440


Steering/Brakes Repair Specifications and Special Tools 60-00-1

Section 60 STEERING/BRAKES REPAIR



SpeCifications Power Steering ........ . . . . . . . . . . . .. 60-00-1 Power Brakes ...................... 60-00-2

Special Tools ......................... 60-00-3

GROUP 05 - POWER STEERING

Steering Column and Metering Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-05-1 Disassembly and Inspection .......... 60-05-3 Steering Column .................... 60-05-3 Metering Pump ..................... 60-05-4

Steering Pump and Column Assembly ... 60-05-4 Steering Valve Repair ................. 60-05-6

Removal ........................... 60-05-7 Disassembly and Inspection .......... 60-05-7 Assembly .......................... 60-05-7

Steering Motor Repair Steering Motor Access. . . . . . . . . . . . . .. 60-05-8 Disassembly ........................ 60-05-9 Inspection . . . . . . . . . . . . . . . . . . . . . . . .. 60-05-11 Assembly ......................... 60-05-12

GROUP 10 - POWER BRAKES

Pistons, Plates, and Disks Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-10-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60-10-1 Assembly and Installation ............ 60-10-2

Brake Valve Removal ......................... " 60-10-2 Disassembly ........................ 60-10-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . .. 60-10-3 Assem bly .......................... 60-10-4 Installation and Adjustment. .......... 60-10-5 Brake Accum ulator . . . . . . . . . . . . . . . . .. 60-10-6

Group 00 SPECIFICATIONS AND SPECIAL TOOLS

SPECIFICATIONS

Power Steering

Friction spring-Free length ....................................................... 0.735 in. (18.67 mm) -Compressed .................................................... 0.52 in. at 81 to 99 Ibs.

(13.2 mm at 360 to 440 N) Steering motor piston 0.0 . ........................................ 3.122 to 3.124 in. (79.287-79.337 mm) Steering motor piston sleeve 1.0 .................................... 3.125 to 3.127 in. (79.375-79.425 mm) Feedback piston pin

Length .......................................................................... 2.58 in. (65.6 mm) 0.0 ...................................................... 0.7357 to 0.7363 in. (18.719 to 18.734 mm)

Feedback piston pin bore 1.0 .................................. 0.7365 to 0.7375 in. (18.739 to 18.765 mm) Feedback piston pin spring

-Free length .................... " ............................................ 1.16 in. (29.464 mm) -Compressed. . . . . . . . . . .................................................. 0.74 in. at 45 to 55 Ibs.

(18.8 mm at 200 to 244 N) Feedback piston 0.0 . ............................................. 1.499 to 1.500 in. (38.14 to 38.17 mm) Feedback piston bushing

1.0 ............................................................ 1.501 to 1.506 in. (38.27 to 38.32 mm) 0.0 ...................................................... 1.8515 to 1.8525 in. (47.110 to 47.135 mm)

TM-11B2 (Jun-BO) Litho in U.S.A. Tractor - 4440


Hydraulic Repair . Specifications and Special Tools 70-00-1

Section 70 HYDRAULIC REPAIR



Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 70-00-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . .. 70-00-7 Making Special Tools ................. 70-00-13

GROUP 05 - MISCELLANEOUS HYDRAUliC COMPONENTS

Charging Circuit Valves. . . . . . . . . . . . . . .. 70-05-1 QUAD-RANGE Transmission Equipped

Tractors. . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-1 Oil Pressure Regulating Valve

Housing ....................... 70-05-1 Removal ...................... . Inspection ..................... . Assembly and Installation ....... .

Oil Filter Relief Valve Housing .... . Removal ...................... . Inspection ..................... . Assembly and Installation ....... .

Power Shift Transmission Equipped Tractors ......................... . Oil Pressure Regulating Valve

Housing ...................... . Removal ...................... . Inspection ..................... . Assembly and Installation ....... .

Function Return Oil Filter Relief Valve .. . Removal .......................... . Inspection ......................... . Assembly and Installation ........... .

Oil Cooler Check Valve ............... . Removal .............. . Inspection ......................... . Installation ......................... .

Pressure Control Valve ............... . Removal .......................... . Inspection and Repair .............. . Assembly and Installation ........... .

Directional Control Valve .............. . Repair ............................ . Assembly and Installation ........... .

Hydraulic Oil Cooler .................. . Repair ............................ . Removal .......................... . Inspection ......................... . Installation ........ .


70-05-1 70-05-1 70-05-2 70-05-2 70-05-2 70-05-2 70-05-3

70-05-4

70-05-4 70-05-4 70-05-4 70-05-5 70-05-5 70-05-5 70-05-5 70-05-6 70-05-6 70-05-6 70-05-6 70-05-6 70-05-7 70-05-7 70-05-7 70-05-8 70-05-8 70-05-8 70-05-8 70-05-9 70-05-9 70-05-9 70-05-9 70-05-9

Seat Valve Housing ................... 70-05-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-9 Disassembly ....................... 70-05-10 Inspection and Repair .............. 70-05-10

Charging the Accumulator ............. 70-05-11 Transmission-Hydraulic Oil System

Cleanup Procedure ................. 70-05-13

GROUP 10 - HYDRAUliC PUMPS External Gear Pump (QUAD-RANGE

Transmission) ...................... . Removal .......................... . Inspection and Repair .............. . Assembly and Installation ........... .

Internal Gear Pump (Power Shift Transmission) ................... . Removal and Disassembly .......... . Repair and Assembly ............... .

Replacing Main Pump Shaft Oil Seal ... . Remov~ .......................... . Installation ......................... .

70-10-1 70-10-1 70-10-1 70-10-2

70-10-2 70-10-2 70-10-3 70-10-5 70-10-5 70-10-5

Main Hydraulic Pump .................. 70-10-6 Removal .. . . . . . . . . . . . . . . . . . . . . . . . .. 70-10-6 Repair ............................. 70-10-7 Assembly and Adjustments .......... 70-10-11 Installation and Adjustments ......... 70-10-14

GROUP 15 - ROCKS HAFT AND IMPLEMENT HITCHES

Rockshaft Piston Cover . . . . . . . . . . . . . . .. 70-15-1 Rockshaft Housing .................... 70-15-3 Control Valve Housing ................. 70-15-7

Operating Linkage .................. 70-15-10 Load Control Arm .... . . . . . . . . . . . . . . .. 70-15-13 Console Linkage ..................... 70-15-16 Adjustments ......................... 70-15-16 Hitch ................................ 70-15-20 Lift Assist. ........................... 70-15-21 Power Weight Transfer Hitch .......... 70-15-23

GROUP 20 - SELECTIVE CONTROL VALVE AND REMOTE CYliNDER

Breakaway Coupler. . . . . . . . . . . . . . . . . . .. 70-20-1 SCV Housing. . . . . . . . . . . . . . 70-20-3 SCV Adjustment ...................... 70-20-8 Remote Cylinder ..................... 70-20-11

Tractor - 4440


Miscellaneous Specifications and Special Tools 80-00-1

Section 80 MISCELLANEOUS


GROUP 00 - SPECiFiCATIONS ............ 00-1

GROUP 05 - FRONT AXLES Adjustable Tread Axle

Checking Pivot Pin Bushing Wear ............................... 05-1

Removal ... . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-1 Inspection and Repair . . . . . . . . . . . . . . . . .. 05-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-2

Knee Assembly Removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-3 Inspection and Repair ................. , 05-3 Assembly and Installation . . . . . . . . . . . . . .. 05-4

Toe-In Adjustment. ....................... 05-5 Power Front Wheel Drive Axle. . . . . . . . . . . .. 05-5

GROUP 10 - WHEELS Front Wheels

Removal, Inspection and Repair ......... 10-1 Assembly ............................. 10-1

Rear Wheels . Removal .... . . . . . . . . . . . . . . . . . . . . . . . . .. 10-2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3

Rear Wheel Tread. . . . . . . . . . . . . . . . . . . . . . .. 1 0-3 Double Rear Wheels ..................... 10-3


SPECIFICATIONS

Front Axles

ITEM SPECIFICATIONS Axle pivot pin bushing 1.0. (assembled) ............................. 1.497 to 1.503 in. (38.01 to 38.16 mm) Axle pivot pins (front and rear) 0.0 ................................. 1.494 to 1.495 in. (37.95 to 37.97 mm) Knee bushing 1.0 ................................................... 1.747 to 1.753 in. (44.4 to 44.5 mm) Front axle pivot bolt shims .......................................................... 0.015 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) .................................. 370 ft-Ibs (502 Nm) (50.2 kgm) Tie rod end-to-steering arm nut ........................................... 100 ft-Ibs (135 Nm) (13.5 kgm)

TM-1182 (Sep-77) Litho in U. S.A. Tractor - 4440


Operator Station Repair Specifications and Special Tools 90-00-1

Section 90 OPERATOR STATION REPAIR



Specifications

Page

Air Conditioning System ................ 00-3 Cap Screw Torque Chart ............... 00-4

Special Tools ............................ 00-5

GROUP 05 - AIR CONDITIONING SYSTEM Refrigerant Couplings

General Information .................... 05-1 Service ............................... 05-1

Compressor Removal ..................... 05-2 Leak Testing Compressor ................. 05-2

Voltmetric Efficiency Test ............... 05-2 Shaft Seal Leak Test ................... 05-3

Compressor Clutch and Shaft Seal Assembly ................................ 05-4

Disassembly ........................... 05-5 Assembly ............................. 05-8

Checking and Adding Compressor Oil ..... 05-12 General Information . . . . . . . . . . . . . . . . . .. 05-12 When Servicing Compressor ........... 05-12 When Servicing System Components

Other Than Compressor. . . . . . . . . . . . . 05-13 Compressor Installation .................. 05-13 Condenser, Receiver-Dryer, and Evaporator

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-14 General Information ................. 05-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-14 Repair ............................. 05-14 Installation ......................... 05-14

TM-1182 (Feb-79) Litho in U. S.A.

GROUP 05 - AIR CONDITIONING SYSTEM-Continued

Receiver-Dryer

Page

General Information ................. 05-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-15 Repair ............................. 05-15 Installation ......................... 05-15

Evaporator General Information .......... ' ..... " 05-16 Removal ......................... " 05-16 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-16 Installation ......................... 05-16

Regulatory Controls Expansion Valve

General Information ............... " 05-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-17 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-18 Installation ......................... 05-18

Temperature Control Switch General Information ................. 05-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-18 Installation ......................... 05-19

Compressor Relief Valve General Information ............... " 05-19 Removal ......................... " 05-19 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-19 Installation ......................... 05-19

Air Intake System Pressurizer Blowers and Switch

General Information ................. 05-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-21 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 ......................... 05-22

Tractor - 4440


90-00-2 Specifications and Special Tools Operator Station Repair

CONTENTS OF THIS SECTION-Continued

Page

GROUP 10 - HEATING SYSTEM System Components

Heater Valve General Information . . . . . . . . . . . . . . . . .. 10-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Installation .......................... 10-1

Heater Core General Information .................. 10-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Installation .......................... 10-2

Heater Blowers . . . . . . . . . . . . . . . . . . . . . . .. 10-2 Heater Pipes and Hoses. . . . . . . . . . . . . . .. 10-2

GROUP 15 - SEAT Servicing Seat Components . . . . . . . . . . . . . .. 15-1 Removal ................................ 15-1 Armrest Assembly

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2

Cushions and Seat Belts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3 Repair .............................. " 15-4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4

Horizontal Support Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-6

Swivel Assembly Removal .............................. 15-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-6

Vertical Suspension Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-8 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-8 Installation and Adjustment. . . . . . . . . . . . .. 15-8

TM-1182 (Feb-79) Litho in U.S.A.

Page

GROUP 20 - MISCELLANEOUS COMPONENTS Sound-Gard Body Frame

General Information .................... 20-1 Repair ................................ 20-1

Body Door and Door Panels General Information . . . . . . . . . . . . . . . . . . .. 20-2 Removal

Door .............................. " 20-2 Door Stop ........................... 20-2 Door Handle and Latch. . . . . . . . . . . . . .. 20-2 Door Panel .......................... 20-3

Hinge Replacement Replacing The Upper or Center

Hinge ............................... 20-3 Replacing Lower Hinge ................. 20-4 Replacing All Three Hinges or

Door ................................ 20-5 Exterior Panels

General Information . . . . . . . . . . . . . . . . . . .. 20-6 Removal

Rear Panels ......................... 20-6 Side Panels ......................... 20-7

Installation ............................. 20-7 Roof Panels

Removal Outer Roof . . . . . . . . . . . . . . . . . . . . . . . . .. 20-8 Inner Roof . . . . . . . . . . . . . . . . . . . . . . . . .. 20-8

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-9 Glass and Attaching Hardware;

Moldings and Seals General Information ............... . . .. 20-11 Removal ............................ , 20-11 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-12

Control Support with Covers and Cowl General Information ................... 20-13 Service .............................. 20-13

Headliner and Upholstery Removal

Front Headliner .................... , 20-15 Rear Head Ii ner .................... , 20-15

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-15 Radio, Tape Player and Windshield

Wiper Motors . . . . . . . . . . . . . . . . . . . . . . . .. 20-15

Tractor_ =- 4440


Miscellaneous Options Specifications 95-00-1

Section 95 MISCELLANEOUS OPTIONS

(Not Used In U.S. and Canada) CONTENTS OF THIS SECTION

Page

GROUP 00 - SPECIFICATIONS Mechanical Hand Brake. . . . . . . . . . . . . . .. 95-00-2 Auxiliary Trailer Brakes ................ 95-00-2

GROUP 50 - MECHANICAL HAND BRAKE General Information ................... 95-50-1 Removal ............................. 95-50-5 Inspection .. . . . . . . . . . . . . . . . . . . . . . . . . .. 95-50-5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 95-50-5


Page

GROUP 60 - AUXILIARY TRAILER BRAKES How the Trailer Brake Valve Works .... , 95-60-1 Brake Valve Removal. . . . . . . . . . . . . . . . .. 95-60-2 Inspection ........................... , 95-60-3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 95-60-3 Testing Brake Valve Assembly .......... 95-60-6

Tractor - 4440


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 05 - System Operation Checking Valve Lift ..................... 220-10-3 Cooling System ...................... 220-05-1 Checking Valve Clearance ............... 220-10-4 Lubrication System .. . . . . . . . . . . . . . . . .. 220-05-2 Checking Crankshaft End Play ........... 220-10-5

GROUP 10 - System Tests and Diagnosis Checking Damper Run-out .............. 220-10-5 Dynamometer Test ................... 220-10-1 Checking Oil Pressure .................. 220-10-5 Engine-PTO Speed Relationship ....... 220-10-1 Testing Cooling System ................. 220-10-6 Instructions for Engine Break-in ........ 220-10-2 Diagnosing Engine Malfunctions .......... 220-10-6 Testing Compression Pressure ........ 220-10-2


SPECIFICATIONS

Engine oil pressure .................................. 40 to 50 psi (2.75 to 3.75 bar) (3.80 to 3.86 kg/cm2) Compression pressure ......................... 330 to 370 psi (22.79 to 25.52 bar) (23.21 to 22.04 kg/cm2)

at 200 to 250 rpm Radiator leakage test .................................................... 18 psi (1.24 bar) (1.26 kg/cm2) Valve lift

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)

Valve Clearance Intake valves .................................................................... 0.018 in. (0.5 mm) Exhaust valves ................................................................... 0.028 in. (0.7 mm)

Crankshaft end play ...................................... (New part) 0.0015 to 0.015 in. (0.04 to 0.4 mm) (Maximum acceptable) 0.0150 in. (0.38 mm)

Damper radial run-out ...................................................... 0.040 in. (1.0 mm) maximum

TOOL

R 27489N

Fig. 1-Compression Test Equipment

' ... -. R 2749QN

Fig. 2-0il Pressure Test Equipment

TM-1182 (Feb-79) Litho in U.S.A.

SPECIAL TOOLS NUMBER A - 0-14547BA

Motorite Testor*

B - 0-14557BA Adapter*

A - 0-1 Fitting* B - 19-HP Hose

End Fitting* C - 0-20 Gauge*

USE Used for testing compression pressure.

Used for testing oil pressure.

*Order from Service Tools, Box 314, Owatonna, MN 55060

Tractor - 4440


Fuel/Air Operation and Tests Specifications and Special Tools 230-00-1

Section 230 FUEL/AIR OPERATION AND TESTS



Specifications

Page

Air Intake System ...................... 00-2 Diesel Fuel System .................... 00-2 Control Linkage . . . . . . . . . . . . . . . . . . . . . . .. 00-3

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-3

GROUP 05 - AIR INTAKE SYSTEM How The System Works . . . . . . . . . . . . . . . . .. 05-1 Diagnosing System Malfunctions. . . . . . . . . .. 05-2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-3 Restriction Indicator

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-3 AiResearch T -048 Turbo-

charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-5 Schwitzer 3LM Turbochargers . . . . .. . . . . . .. 05-5 Diagnosing Turbocharger

Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . .. 05-6 Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . .. 05-7 Intercooler and Intake Manifold ... . . . . . . . .. 05-7 Ether Starting Aid ... . . . . . . . . . . . . . . . . . . . .. 05-8

TM-1182 (Sep-77J Litho in U.S.A.

Page

GROUP 10 - DIESEL FUEL SYSTEM How The System Works .. . . . . . . . . . . . . . . .. 10-3 Diagnosing System Malfunctions. . . . . . . . . .. 10-4 Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . .. 10-6 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-7 Bleeding Fuel System .................... 10-9 Fuel Injection Pump

How The Fuel Injection Pump Works ....................... 10-10

Diagnosing Malfunctions ............... 10-10 Adjustments ........................ " 10-11

Aneroid ................................ 10-15 Hydraulic Aneroid Activator ............. " 10-16 Fuel Injection Nozzles

General Information ................. " 10-17 How The Fuel Injection

Nozzle Works ...................... 10-18 Diagnosing Malfunctions ............... 10-19

GROUP 15 - CONTROL LINKAGE Speed Control Linkage. . . . . . . . . . . . . . . . . . .. 15-1 Foot Throttle Linkage. . . . . . . . . . . . . . . . . . . .. 15-3 Diesel Fuel Shut-Off Control .............. , 15-4

Tractor - 4440


Electrical Operation and Tests Specifications and Special Tools 240-00-1

Section 240 ELECTRICAL OPERATION AND TESTS


Page

GROUP OO-SPECIFICATIONS AND SPECIAL TOOLS

General Information .................. 240-00-2 Charging Circuit ...................... 240-00-3 Lighting Circuits ...................... 240-00-3 Instrument and Accessory Circuits ..... 240-00-4 Power Front-Wheel Drive ............. 240-00-5 Special Tools ........................ 240-00-6

GROUP 05-GENERAL INFORMATION AND DIAGRAMS

General Diagnosis .................... 240-05-1 Precautions. . . . . . . . . . . . . . . . . . . . . . . . .. 240-05-6 Electrical Diagnostic Kit ............... 240-05-6 Wiring Diagrams ..................... 240-05-9 Circuit Breakers ..................... 240-05-20 SOUND-GARD Body Relay .......... 240-05-21

GROUP 06-ELECTRICAL SYSTEM DIAGNOSIS Electrical Diagnosis Kit. . . . . . . . . . . . . . .. 240-06-1 Electrical System Diagnosis .......... , 240-06-2

GROUP 10-CHARGING SYSTEM General Information .................. 240-10-1 How the System Works. . . . . . . . . . . . . .. 240-10-1 Precautions. . . . . . . . . . . . . . . . . . . . . . . . .. 240-10-4

GROUP 15-STARTING CIRCUIT General Information .................. 240-15-1 How the System Works. . . . . . . . . . . . . .. 240-15-1 Key Switch Continuity Check .......... 240-15-3


Page

GROUP 20-LlGHTING CIRCUITS General Information . . . . . . . . . . 240-20-1 Flood Lamps ......................... 240-20-3 Head Lamps and Tail Lamps. . . . 240-20-4 Turn Signals and Warning Lamps. . ... 240-20-4 Light Switch .................... 240-20-5 Instrument, Indicator, and Console

Lamps . . . . . . ................... 240-20-5 Dome Lamp ......................... 240-20-6 Bulb Replacement .................... 240-20-6

GROUP 25-INSTRUMENT AND ACCESSORY CIRCUITS

Instrument Cluster .................... 240-25-1 Accessories. . . . . . . . . . . . . . . . . . . . . . . . .. 240-25-4 Additional Accessories ............... 240-25-10

GROUP 30-POWER FRONT-WHEEL DRIVE How the System Works ............... 240-30-1 Electrical Tests ....................... 240-30-3

GROUP 35-REMOTE ELECTRICAL CIRCUITS Electrical Remote Control " ........... 240-35-1 Outlet Socket . . . . . . . . . . . . . . . . . . . . . . .. 240-35-4

Tractor - 4440·


Power Train Operation and Tests Specifications and Special Tools 250-00-1

Section 250 POWER TRAIN OPERATION AND TESTS


Page

Group OO-Specifications and Special Tools Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .. 00-3

Group 05-Quad-Range System Operation General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-1 Operating and Lubrication Circuit .......... 05-3 Transmission Oil Pump ................... 05-3 Oil Filter Relief Valve Housing. . . . . . . . . . . .. 05-5 Oil Pressure Regulating Valve Housing ..... 05-5 Clutch Valves. . . . . . . . . . . . . . . . . . . . . . . . . . .. 05-6 Oil Cooler Check Valve ................... 05-7 Lubrication Reduction Valve ............... 05-7 Quad-Range Planetary. . . . . . . . . . . . . . . . . . .. 05-9

Power Flow .......................... 05-11 Control and Shift Valves ............... 05-11

Quad-Range Eight Speed ................ 05-14 PTa ................................... 05-15

Group 10-Quad-Range Tests and Diagnosis Diagnosing Malfunctions (General) . . . . . . . .. 10-1 Clutch Pressure Test ..................... 10-4 Lubrication Pressure Test . . . . . . . . . . . . . . . .. 10-5 Lubrication Reduction Valve Test ........ " 10-6 Circuit Leakage Isolation Test . . . . . . . . . . . .. 10-6 PTa 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 PTa .................................... 15-8

Page

Group 20-Power Shift Tests and Diagnosis Testing System Pressure. . . . . . . . . . . . . . . . .. 20-1 Testing Control Pressure .................. 20-2 Lubrication Pressure Test ................. 20-4 Testing PTa Clutch and Brake Pressure .... 20-4 Oil Flow Troubleshooting Illustrations ....... 20-5 Power Shift Diagnosis .... . . . . . . . . . . . . . . .. 20-6

Group 25-Differential and Final Drive How The System Works . . . . . . . . . . . . . . . . .. 25-3 Differential Lock Valve Pressure Test. ...... 25-4

Group 30-Power Front-Wheel Drive Electrical Control System. . . . . . . . . . . . . . . . .. 30-1 Control Valve Housing .................... 30-2 Wheel Oil Manifold ....................... 30-4 Wheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . .. 30-5 Planetary and Brake . . . . . . . . . . . . . . . . . . . . .. 30-6 Power and Oil Flows

Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-6 Forward-Low Torque ................... 30-8 Forward-High Torque ................ " 30-10 Reverse-Low Torque .... " ............ 30-12 Reverse-High Torque. . . . . . . . . . . . . . . . . . 30-14

Diagnosing Malfunctions (General) ...... " 30-16 Testing

Pressure Control Valve ................ 30-18 Bleed Leakage. . . . . . . . . . . . . . . . . . . . . . .. 30-18

TM-1182 (Apr-8t) Litho in U. S.A. Tractor - 4440


Hydraulic Operation and Tests Specifications and Special Tools 270-00-1

Section 270 HYDRAULIC OPERATION AND TESTS



Specifications . . . . . . . . . . . . . . . . . . . . . . .. 270-00-2 Special Tools ........................ 270-00-3 Making Special Tools ............... " 270-00-8

GROUP 05 - HYDRAULIC SYSTEM OPERATION How The Hydraulic System Works ... " 270-05-1

QUAD-RANGE Transmission ........ 270-05-2 Power Shift Transmission ......... " 270-05-5

Hydraulic System Valves. . . . . . . . . . . . .. 270-05-7 Valves in QUAD-RANGE

Transmission .................... 270-05-7 Oil Cooler Lube Check Valve ..... 270-05-7 Oil Filter Relief Valve ............. 270-05-7 Return Oil Check Valve .......... 270-05-8 Oil Pressure Regulating Valve ... " 270-05-8 Oil Cooler Check Valve. . . . . . . . . .. 270-05-9

Valves In Power Shift Transmission Equipped Tractors ............... 270-05-9 Hydraulic Function Oil Filter

Relief Valve ................... 270-05-9 Transmission Oil Filter Relief

Valve ........................ 270-05-11 Oil Cooler Relief Valve .......... 270-05-12 Lube Relief Valve ............... 270-05-12 Oil Pressure Regulating Valve .... 270-05-12 Return Oil Check Valve ......... 270-05-12

Pressure Circuit Valves ............ 270-05-13 Pressure Control Valve .......... 270-05-14

Directional Control Valve ........... 270-05-15 How The Directional Control

Valve Works ................. 270-05-16

GROUP 10 - HYDRAULIC SYSTEM TESTS General Information .................. 270-10-1 How To Use Step-by-Step Hydraulic

Diagnosis Charts. . . . . . . . . . . . . . . . . . . 270-10-1 Safety Instructions ..................... 270-10-2 Fitting Guide For Hydraulic Testing ..... 270-10-3 Contents For QUAD-RANGE Diagnosis. 270-10-6 Heating The Hydraulic Oil ............. 270-10-7 Preliminary Checks (QUAD-RANGE

Transm iss ion) . . . . . . . . . . . . . . . . . . . . . . 270-10-8 QUAD-RANGE Transmission Charts .. 270-10-10 Test Data Sheet .................... 270-10-27 Contents For Power Shift Diagnosis ... 270-10-28

TM-1182 (Jun-80) Litho in U. S.A.

Preliminary Ch~cks (Power Shift Transmission) ..................... 270-10-29

Power Shift Transmission Charts ...... 270-10-31 Test Data Sheet ..................... 270-10-48

GROUP 15 - MISCELLANEOUS HYDRAULIC COMPONENTS

HYDRACUSHIONEDTM Seat ........... 270-15-1 Checking Discharge Flow Rate ...... 270-15-5 Testing Pressure Regulating Valve. " 270-15-5 Adjusting Pressure Regulating Valve . 270-15-5

Main Hydraulic Oil Reservoir .......... 270-15-5 Hydraulic Oil Reservoir ........... : ... 270-15-6 Hydraulic Oil Filter. . . . . . . . . . . . . . . . . . .. 270-15-6 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . .. 270-15-6 Hydraulic Oil Attenuator . . . . . . . . . . . . . .. 270-15-7

GROUP 20 - HYDRAULIC PUMP Transmission Pumps ................. 270-20-1

How The Pumps Work ............. 270-20-1 Operation Of External Gear Pump

(QUAD-RANGE Transmission) .. Operation Of Internal Gear Pump

(Power Shift Transmission) ..... 270-20-1 Testing The External Gear Pump

(QUAD-RANGE Transmission) .... 270-20-2 Testing The Internal Gear Pump

(Power Shift Transmission) ....... 270-20-5 Diagnosing Malfunctions ............ 270-20-7

Main Hydraulic Pump ................. 270-20-8 How The Main Pump Works ........ 270-20-8 Diagnosing Malfunctions ............ 270-20-9

GROUP 25 - ROCKSHAFT AND IMPLEMENT HITCHES

How The Rockshaft Works . . . . . . . . . . .. 270-25-1 Diagnosing Malfunctions .............. 270-25-6 Adjustment Checks ................... 270-25-9 Testing ............................. 270-25-14 Rockshaft Air Leakage Tests ......... 270-25-17 Lift-Assist. .......................... 270-25-21 Power Weight-Transfer .............. 270-25-22

GROUP 30 - SELECTIVE CONTROL VALVE AND REMOTE CYLINDER

How The System Works . . . . . . . . . . . . .. 270-30-1 Diagnosing Malfunctions ............. 270-30-10 Testing ............................. 270-30-11 Selective Control Valve Air

Leakage Tests . . . . . . . . . . . . . . . . . . . . 270-30-14

Tractor - 4440


Operator Station Operation and Tests Specifications and Special Tools 290-00-1

Section 290 OPERATOR STATION

OPERATION AND TESTS CONTENTS OF THIS SECTION

Page GROUP 5 - AIR CONDITIONING

SYSTEM OPERATION How The System Works .................... 05-1 Electrical Testing ........................... 05-3 Service Valves ............................ , 05-3 Refrigerant Couplings

How the Couplings Work. . . . . . . . . . . . . . . . .. 05-6 Compressor

How the Compressor Works ............... 05-7 Receiver-Dryer

How the Receiver-Dryer Works ............ 05-8 Regulatory Controls

Expansion Valve How the Expansion Valve Works . . . . . . .. 05-8

Thermostatic Temperature Control Switch How the Switch Works ................. 05-8

Compressor Relief Valve How the Relief Valve Works ............ 05-9

GROUP 10 - AIR CONDITIONING SYSTEM TESTS

General Information ......................... 10-1 Preliminary Checks ....................... :. 10-1 How to Use Step-by-Step Air Conditioning

Diagnosis Charts. . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . .. 10-2 Air Conditioning Diagnosis Charts ............ 10-3 Discharging the System . . . . . . . . . . . . . . . . . . .. 10-22 Flushing the System . . . . . . . . . . . . . . . . . . . . . .. 10-22 Adding Refrigerant Oil to the System . . . . . . .. 10-23 Purging the System. . . . . . . . . . . . . . . . . . . . . . .. 10-24 Evacuating the System. . . . . . . . . . . . . . . . . . . .. 10-24 Charging the System ...................... 10-25 Leak Testing the System. . . . . . . . . . . . . . . . . .. 10-26


GROUP 15 - HEATING SYSTEM OPERATION AND TESTS

Page

How the System Works . . . . . . . . . . . . . . . . . . . .. 15-1 Diagnosis and Testing

Preliminary Checks ..................... " 15-2 Electrical Testing ......................... 15-2

Diagnosing Malfunctions ................... " 15-2

GROUP 20 - SEAT (See Section 270 Hydraulic Operation and Tests for information regarding the Hydracushioned™ Seat.) Hydracushioned Seat Suspension

Diagnosis ............................. 20-1

Tractor - 4440


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