John Deere 1840 | 2240 | 2440 | 2640 Service Manual€¦ · · 2017-11-06John Deere MODEL: 2440 &...

John Deere

MODEL:

2440 & 2640 Tractors SIN 0-340999

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-TM1142

http://www.jensales.com/products/john-deere-tractor-service-manual-jd-s-tm1142.html

Make: John Deere Model: 2440 Years Made: 1976-

RIGHT SIDE OF TRACTOR FRAME Paint Codes 1982

HP-PTO: 60.62 HP-Engine: HP-Drawbar: 52.3 Year Beginning Serial Numbe Location MFG Color Name

HP-Range: 61 Engine-Make: Engine-Fuel:

JD DIESEL 1976 235210

Body I NEW AG GREEN

Engine-Cyl(s)-CID: Transmission-Optional: HI-La

4/219 STD: SG 1977 258106

Wheels & Trim Classic Yellow

Fwd/Rev Standard: Fwd/Rev Mfwd-Std/Opt:

8/4 Optional: 16/8 1978 280789

Tires-Std Front: Tires-Std Rear: Wheelbase-Inch:

6.00-16 16.9-28 87.8 1979 305501

Pto Type: IND Pto Speed: 540 CAT 1-3pt Hitch:

1000 False 1980 341000

CAT 11-3pt Hitch: CAT 111-3pt Hitch Lift:

True Hitch: False 1981 362173

Hydraulics-Type: Hyd-Cap: 10

CLOSED Hyd-Flow: 6 1982 376746

Hyd Std Outlets: Cooling Fuel Tank

Capacity: 12 Capacity: 19.5

r:-Stdm A/C; Rops:

Weight: 4750 New Price: 18583

Make: John Deere Model: 2640 Years Made: 1976-1982

RIGHT SIDE OF TRACTOR FRAME Paint Codes

HP-PTO: 70 HP-Engine: HP-Drawbar: Year Beginning Serial Numbe Location MFG Color Name

HP-Range: 70 Engine-Make: Engine-Fuel:

JD DIESEL 1976 235313

Body I CLASSIC GREEN

Engine-Cyl(s)-CID: Transmission-Optional: HI-La

4/276 STD: SG 1977 258106

Wheels & Rims Classic Yellow

Fwd/Rev Standard: Fwd/Rev Mfwd-Std/Opt:

8/4 Optional: 16/8 1978 280789

Tires-Std Front: Tires-Std Rear: Wheelbase-Inch:

6.00-16 16.9-28 87.8 1979 305505

Pto Type: IND Pto Speed: 540 CAT 1-3pt Hitch:

1000 False 1980 341000

CAT 11-3pt Hitch: CAT 111-3pt Hitch Lift:

True Hitch: False 1981 362175

Hydraulics-Type: Hyd-Cap: 10 Hyd-Flow: 6

CLOSED 1982 376744

Hyd Std Outlets: Cooling Fuel Tank

Capacity: 12 Capacity: 19.5 Cab-Stdm A/C;

Weight: 4930 New Price: 21150 Rops:


2440 AN D 2640 TRACTORS

(SIN -340999)

TECHNICAL MANUAL 2440 AND 2640 TRACTORS

(SIN -340999)

TM1142 (01 MAR81) English

JOHN DEERE TRACTOR WORKS

TM1142 (01MAR81)

UTHO IN THE U.S.A.

ENGLISH


2440 AND 2640 TRACTORS

(Serial No. -340999)

TECHNICAL MANUAL TM-1142 (Sep-75)

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.

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GENERAL 10

ENGINE 20

FUEL SYSTEM 30

ELECTRICAL SYSTEM 40

POWER TRAIN 50

STEERING AND BRAKES 60

HYDRAULIC SYSTEM 70

MISCELLANEOUS 80


Tractors - 2440 and 2640 TM-1142 (Jan-78)

General 10 General Tractor Specifications - 2440 Tractor 5-1

Section 10 I GENERAL

CONTENTS OF THIS SECTION

Page

GROUP 5 - GENERAL TRACTOR SPECIFICATIONS (2440) ....... 5-1

GROUP 7 - GENERAL TRACTOR SPECIFICATIONS (2640) ....... 7-1

GROUP 10 - PREDELIVERY, DELIVERY, AND AFTER-SALE SERVICES

Predelivery Service. . . . . . . . . . . . . . . . . . . . . .. 10-1 Delivery Service ......................... 1 0-4 After-Sale Inspection . . . . . . . . . . . . . . . . . . . .. 10-4

GROUP 15 - TUNE-UP Preliminary Engine Testing. . . . . . . . . . . . . . .. 15-1 Engine Tune-Up ........ . . . . . . . . . . . . . . . .. 15-1 Tractor Tune-Up . . . . . . . . . . . . . . . . . . . . . . . .. 15-3

GROUP 20 - LUBRICATION Lubrication Chart................ . . . . . . . .. 20-1 Engine Lubricating Oils. . . . . . . . . . . . . . .. . .. 20-2 Transmission Hydraulic Oils. . . . . . . . . . . . . .. 20-2 Greases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-2 Storing Lubricants........................ 20-2

GROUP 25 - SEPARATION (2440) Separating Tractor Front End

Page

From Engine .......................... 25-1 Removing Engine . . . . . . . . . . . . . . . . . . . . . . .. 25-2 Separating Engine From Clutch

Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25-3 Separating Clutch Housing From

Transmission Case ..................... 25-5 Removing Final Drive Assembly ........... 25-6

GROUP 27 - SEPARATION (2640) Separating Tractor Front End

From Engine . . . . . . . . . . . . . . . . . . . . . . . . .. 27-1 Removing Engine ........................ 27-2 Separating Engine From Clutch

Housing ............................... 27-3 Separating Clutch Housing From

Transmission Case ..................... 27-5 Removing Final Drive Assembly. . . . . . . . . .. 27-6

GROUP 30 - SPECIFICATIONS AND SPECIAL TOOLS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-1 Torque Chart ............................ 30-2

Group 5 GENERAL TRACTOR SPECIFICATIONS (2440)

ENGINE Maximum PTO horsepower* .. 60.65 (45.23 kW) Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . .. 4 Bore and stroke .......... .4.02 in. (102 mm) x

4.33 in. (110 mm) Displacement ............... 219 in.3 (3590 cm3) Compression ratio . . . . . . . . . . . . . . . . . . .. 16.8 to 1 Firing Order ........................... 1-3-4-2 Intake valve clearance ...... 0.014-in. (0.35 mm) Exhaust valve clearance .... 0.018-in. (0.46 mm) Slow idle ............................. 800 rpm Fast idle ............................ 2650 rpm

*Official test at 2500 engine rpm (650 or 1210 PTO rpm)

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ELECTRICAL SYSTEM Battery dry voltage. . . . . . . . . . . . . . . . . . .. 12 volts Battery specific gravity at full charge

(corrected to 80°F [2TC]) .............. 1.260 Battery terminal grounded ............. negative

CAPACITIES Fuel tank .................. 19-112 gals. (73.8 L) Cooling system ................ 12 qts. (11.4 L) Crankcase (including filter) ......... 6 qts. (5.7L) Transmission-hydraulic

system ....................... 10 gals. (38 L) Belt pulley .................... 2-112 pts. (0.3 L)

CLUTCH ................... Single or dual stage, spring-loaded, dry

disk, foot-operated.


Tractors - 2440 and 2640 TM-1142 (Sep-75)

Basic Engine 20 General Information and Diagnosis 5-1

Section 20 ENGINE


GROUP 5 - GENERAL INFORMATION AND DIAGNOSIS

Page

General Information ........................ 5-2 Diagnosing Engine Malfunctions ............. 5-2

GROUP 10 - CYLINDER HEAD, VALVES, CAMSHAFT, AND TIMING GEAR TRAIN - 2440 TRACTOR

General Information ...................... 10-1 Diagnosing Malfunctions .................. 10-1 Preliminary Valve Train Checks . . . . . . . . . .. 10-2 Cylinder Head and Valves

Removal and Repair . . . . . . . . . . . . . . . . . .. 10-2 Assembly and Installation ............... 10-4 Valve Clearance Adjustment .......... " 10-4

Camshaft Removal .............................. 10-5 Repair ................................ 10-5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-6

Timing Gear Train. . . . . . . . . . . . . . . . . . . . . . .. 10-7 Removal ....... " ....................... 10-7 Inspection and Repair .................. " 10-7 Assembly and Installation................. 10-9

GROUP 12 - CYLINDER HEAD, VALVES, CAMSHAFT, AND TIMING GEAR TRAIN - 2640 TRACTOR

General Information ...................... 12-1 Diagnosing Malfunctions .................. 12-1 Preliminary Valve Checks................. 12-2 Cylinder Head and Valves

Removal and Repair . . . . . . . . . . . . . . . . . .. 12-2 Assembly and Installation ............... 12-4 Valve Clearance Adjustment . . . . . . . . . . .. 12-5

Camshaft Removal .............................. 12-5 Repair ................................ 12-6 Installation ........................... " 12-6

Timing Gear Train ...................... " 12-7 Removal ............................... " 12-7 Inspection and Repair . . . . . . . . . . . . . . . . . . .. 12-7 Assembly and Installation ................. 12-9

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GROUP 15 - CYLINDER BLOCK, LINERS, PISTONS AND RODS

Page I General Information ...................... 15-1 Diagnosing Malfunctions .................. 15-1 Removal ............................... " 15-2 Repair

Pistons .............................. " 15-2 Liners ............................... " 15-3 Rods ................................ " 15-4

Assembly .............................. " 15-5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-5

GROUP 20 - CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL - 2440 TRACTOR

General Information ...................... 20-1 Diagnosing Malfunctions .................. 20-1 Checking End Play ....................... 20-1 Removal ............................... " 20-2 Inspection and Repair

Crankshaft and Flywheel ............... 20-2 Main Bearings and Journals .......... " 20-2 Rear Crankshaft Oil Seal Housing, Fly-

wheel and Wear Sleeve ............ " 20-3 Assembly .............................. " 20-3 Front Oil Seal and Wear Sleeve ........ " 20-4

GROUP 22 - CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL - 2640 TRACTOR

General Information ...................... 22-1 Diagnosing Malfunctions .................. 22-1 Checking End Play ....................... 22-1 Removal ............................... " 22-2 Inspection and Repair

Crankshaft and Flywheel ............... 22-2 Main Bearings and Journals ............ 22-2 Rear Crankshaft Oil Seal Housing, Fly-

wheel and Wear Sleeve. . . . . . . . . . . . .. 22-3 Assembly ................................ 22-3 Front Oil Seal and Wear Sleeve .......... 22-4


20 Engine 5-2 General Information and Diagnosis

Tractors - 2440 and 2640 TM-1142 (Sep-7S)

CONTENTS OF THIS SECTION-Continued

Page

GROUP 25 - LUBRICATION SYSTEM -2440 TRACTOR

General Information ...................... 25-1 Diagnosing Malfunctions .................. 25-1 Checking Oil Pressure.................... 25-1 Oil Pump

Removal .............................. 25-1 Inspection and Repair.................. 25-1 Assembly and Installation ............... 25-2

Oil Filter................................. 25-3 Oil Pressure Regulating Valve .. ........... 25-3

GROUP 27 - LUBRICATION SYSTEM -2640 TRACTOR

General Information ...................... 27-1 Diagnosing Malfunctions .................. 27-1 Checking Oil Pressure.................... 27-1 Oil Pump

Removal .............................. 27-1 Inspection and Repair .................. 27-1 Assembly and Installation ............... 27-2

Oil Cooler - Filter Assembly .............. 27-3 Oil Cooler Bypass Valve ............... 27-3 Oil Pressure Regulating Valve ........... 27-4 Oil Filter .............................. 27-4

GROUP 30 - COOLING SYSTEM - 2440 TRACTOR

General Information ...................... 30-1 Diagnosing Malfunctions .................. 30-1 Radiator and Fan Belt .................... 30-1 Water Pump..... . . . . . . . . . . . . . . . . . . . . . . .. 30-1 Water Manifold and Thermostats ... . . . . . .. 30-3

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Page

GROUP 32 - COOLING SYSTEM - 2640 TRACTOR

General Information ...................... 32-1 Diagnosing Malfunctions .................. 32-1 Radiator and Fan Belt .................... 32-1 Water Pump............ . . . . . . . . . . . . . . . .. 32-1 Water Manifold and Thermostats .......... 32-3

GROUP 35 - SPECIFICATIONS - 2440 TRACTOR Cylinder Head, Valves, and Camshafts .... 35-1 Cylinder Block, Liners, Pistons, and

Rods .................................. 35-2 Crankshaft, Main Bearings and

Flywheel .............................. 35-3 Lubrication System . . . . . . . . . . . . . . . . . . . . . .. 35-3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . .. 35-3 Engine Break-In............ . . . . . . . . . . . . .. 35-4 Special Tools ............................ 35-4 Special Lubricants........................ 35-4

GROUP 37 - SPECIFICATIONS - 2640 TRACTOR Cylinder Head, Valves, and Camshafts .... 37-1 Cylinder Block, Liners, Pistons, and

Rods .................................. 37-2 Crankshaft, Main Bearings and

Flywheel .............................. 37-3 Lubrication System ....................... 37-3 Cooling System .......................... 37-3 Engine Break-In .......................... 37-4 Special Tools .......................... " 37-4 Special Lubricants ........................ 37-4


20 Engine Tractors - 2440 and 2640 10-6 Cylinder Head, Valves, Camshaft, and Timing Gear Cover - 2440 Tractor TM-1142 (Sep-7S)

Repair-Continued

Inspect camshaft journals (Fig. 8) and bores in block for damage or wear. Excessive wear could indicate excessive end play. 0.0. of journal is 2.1997 to 2.2007 inches (5.5872 to 5.5898 cm). I.D. of the bore is 2.2042 to 2.2052 inches (5.5986 to 5.6012 cm). Maximum allowable clearance is 0.0035 to 0.0055 inch (0.0889 to 0.1397 mm).

New thrust plate thickness is 0.1560 to 0.1580 inch (3.9624 to 4.0132 mm). Maximum wear to 0.1510 inch (3.8354 mm) is acceptable.

If necessary, replace camshaft drive gear by pressing gear from shaft. Support camshaft under first journal. With timing mark of new gear facing away from camshaft, align gear and camshaft keyways, install Woodruff key, and press gear on until tight against cam shoulder.

If necessary, remove tachometer drive shaft by threading shaft end, placing hex. nut on shaft, and pulling from camshaft.

Check camshaft lobes and oil pump drive gear for wear or damage. Replace camshaft if necessary.

Examine cam followers for damage. Replace as necessary.

Installation

If the cam followers have been removed, reinstall, using the magnetic holding tools to hold them away from the camshaft bore until camshaft is installed.

Coat camshaft with a light coat of engine oil and install in cylinder block. Again, take care not to drag cam lobes in bore.

A-Thrust Plate B-Attaching Cap Screws

Fig. 9-lnstalling Camshaft Thrust Plate

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Secure thrust plate with cap screws. Tighten to 35 ft-Ibs (47 Nm). Check camshaft end play.

A-Timing Tool B-Camshaft Gear Timing Mark

Fig. 10-Timing Camshaft Gear

Before installing idler gear, position No.1 piston on TDC on compression stroke. Align camshaft drive gear timing mark (B, Fig. 10) and crankshaft center with JD-254 Timing Tool (A). Install idler gear with thrust washers and cap screws and tighten to 65 ftIbs (88 Nm) torque.

Recheck gear timing.

Check camshaft for 0.0025 to 0.0085 inch (0.0064 to 0.216 mm) end play.

Install cylinder head, push rods, and timing gear cover. Tighten cylinder head as described on page 20-10-4.

Check injection pump timing and valve clearance. See Section 30 for injection pump information.

Install remaining tractor parts.

Glue rocker arm cover gasket on rocker arm cover and install.


Tractors - 2440 and 2640 TM-1142 (Mar-81 )

Fuel System 30 Diagnosing Malfunctions 5·1

Section 30 FUEL SYSTEM


Page

GROUP 5 - DIAGNOSING MALFUNCTIONS .. 5-2

GROUP 10 - AIR INTAKE SYSTEM Air Cleaner

General Information . . . . . . . . . . . . . . . . . . .. 10-1 Removal and Repair................... 10-1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1

Restriction Indicator General Information ................... , 10-2 Testing Indicator Operation. . . . . . . . . . . .. 10-2

GROUP 15 - FUEL SYSTEM Fuel Tank

Removal ............................. , 15-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2

Fuel Pump General Information . . . . . . . . . . . . . . . . . . .. 15-2 Diagnosing Malfunctions................ 15-3 Removal .... ~ . . . . . . . . . . . . . . . . . . . . . . . .. 15-3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3

Fuel Filter............................... 15-4 Bleeding Fuel System . . . . . . . . . . . . . . . . . . .. 15-4 Fuel Injection Pump

General Information . . . . . . . . . . . . . . . . . . .. 15-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-5 Installation. '.' ......................... , 15-6 Automatic Speed Advance Adjustment. .. 15-7

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Page GROUP 15 - FUEL SYSTEM (Continued)

Fuel Injection Nozzles General Information .................. " 15-9 Diagnosing Malfunctions .............. " 15-9 Removal ........................... " 15-10 Repair ............................. " 15-10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-11

G~~~~:tr~~~~~~ LINKAGE ......... 20-1 I Repair .............................. " 20-2 Installation ........................... " 20-2 Adjustment .......................... " 20-4

Fuel Shut-Off Control Linkage Operation and Adjustment ............ " 20-6

GROUP 25 - ETHER STARTING AID General Information ...................... 25-1 Removal ................................ 25-1 Repair .................................. 25-1 Installation ............................. " 25-1


Specifications (2440} ................... " 30-1 Specifications (2640) .................. .-.. 30~2 Special Tools .......................... '. 30-2



A-Shut-Off Valve 8-Fuel Tank C-Injection Nozzle

O-Fuel Pump E-Leak-Off LiIJe F -Fuel Filter G-Injection Pump

Fuel System 30 Fuel System 15-1

Group 15 FUEL SYSTEM

Fig. 1 Fuel System

FUEL TANK

Removal (2440)

Remove side shields, grille screens, and hood.

1. Disconnect fuel gauge sending unit wire (Fig. 2).

2. Disconnect fuel pipe at shut-off valve and drain fuel from tank. Fuel tank capacity is 19 U.S. gallons (72 I).

3. Loosen air intake pipe hose clamps, and remove air cleaner. Remove hydraulic oil reservoir.

4. Remove fuel tank-to-front plate cap screws. Loosen front plate-to-front support cap screws, and slide stops rearward.

5. Disconnect radiator brace rod and fuel return pipe.

Lift out tank, and plug or cap openings to prevent entry of foreign material.

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Fig 2-Fuel Tank Removal Procedures (2440)

I


Tractors - 2440 and 2640 TM-1142 (Jan-78)

Electrical System 40 Information and Diagrams 5-1

Section 40 ELECTRICAL SYSTEM


Page GROUP 5 - INFORMATION AND DIAGRAMS

General Information ........................ 5-2 Circuit Breaker ............................. 5-3 Key Switch ................................ 5-3 Harness Replacement ...................... 5-3 Wiring Diagrams ........................... 5-3 Electrical Remote Control. . . . . . . . . . . . . . . .. 5-10

GROUP 10 - CHARGING CIRCUIT General Information . . . . . . . . . . . . . . . . . . . . .. 10-1 Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1 Tests ................................... 10-1 Testing Battery .......................... 10-1 Testing Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-2

Testing Alternator and Regulator with Voltmeter. . . . . . . . . . . . . . . . . . . . . .. 10-2

Testing Alternator Field Circuit on Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3

Testing Alternator on Tractor Using Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3

Testing Alternator with Regulator on Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3

Testing Regulator ...................... 10-3 Repair .................................. 10-4

Slip Ring Bearing.... . . . . . . . . . . . . . . . . .. 10-5 Drive End Bearing . . . . . . . . . . . . . . . . . . . .. 10-5 Rotor ................................. 10-6 Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 0-6 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-6 Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-7

Assembly ................................ 10-7 Tests After Assembly ..................... 10-8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-8

GROUP 15 - STARTING CIRCUIT General Information . . . . . . . . . . . . . . . . . . . . .. 15-1 Diagnosis and Tests ..................... 15-1

High Resistance Tests ................. 15-1 Solenoid Tests ... ..................... 15-1 Starter No Load Test .................. 15-2

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Page

GROUP 15 - STARTING CIRCUIT (Continued) Neutral Start Switch Adjustment ........... 15-2 Repair ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-2

Solenoid Switch ....................... 15-3 Overrunning Clutch Drive............... 15-3 Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3 Armature. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4 Field Coils ..... . . . . . . . . . . . . . . . . . . . . . .. 15-4 Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-5

GROUP 20 - LIGHTING AND ACCESSORY CIRCUITS

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-1 I General Information .................... 20-1 • Diagnosis and Tests . . . . . . . . . . . . . . . . . .. 20-1 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-1

Turn Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-2 Fuel Gauge ............................. 20-2 Accessories and Instruments .............. 20-2


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25-1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25-1 Circuit Breakers ....................... 25-1 Relay ................................. 25-1 Charging Circuit .. . . . . . . . . . . . . . . . . . . . .. 25-2 Starting Circuit. . . . . . . . . . . . . . . . . . . . . . . .. 25-3 Lighting and Accessory Circuits. . . . . . . .. 25-5

Special Tools ............... ~ . . . . . . . . . . .. 25-5


Tractors - 2440 and 2640 TAA-1142 (Jan-78)

Power Train 50 Clutches 5-1

Section 50 POWER TRAIN

CONTENTS OF THIS SECTION GROUP 5 - CLUTCHES

Page

Single-Stage Clutch General Information ...................... 5-2 Diagnosing Malfunctions .................. 5-2 Angle Link Design (2440) ................ 5-4

Repair ................................ 5-5 Assembly ............................. 5-6 Installation ............................ 5-6 Adjustment ............................ 5-7

Angle Link Design (2640) ................ 5-8 Repair ................................ 5-9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-10 Installation .......................... 5-10 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .. 5-11

Auburn Design ........................ 5-13 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-15 Installation .......................... 5-16 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .. 5-16

Dual-Stage Clutch General Information .................... 5-18 Diagnosing Malfunctions................ 5-19 Repair .............................. " 5-20 Assembly ............................. 5-22 Installation ........................... " 5-23 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-23

Clutch Housing and Controls Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-24

GROUP 10 - HI-LO SHIFT UNIT General Information . . . . . . . . . . . . . . . . . . . . .. 10-1 Testing .................................. 10-5 Diagnosing Malfunctions . . . . . . . . . . . . . . . . .. 10-6 Hi-Lo Unit

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-6 Assembly ............................ 10-10

Control Valve........................... 10-12 Repair .............................. , 10-12 Assembly ............................ 10-13

GROUP 15 - REVERSER General Information . . . . . . . . . . . . . . . . . . . . .. 15-2 Testing ... '.' . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-9 Diagnosing Malfunctions ................ , 15-11 Removal ............................... 15-12 Repair ................................ , 15-14 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-20 Adjustments ............................ 15-22

GROUP 20 - COLLAR SHIFT TRANSMISSION General Information . . . . . . . . . . . . . . . . . . . . .. 20-1 Diagnosing Malfunctions . . . . . . . . . . . . . . . . .. 20-2 Removal ................................ 20-2 Inspection and Repair . . . . . . . . . . . . . . . . . . .. 20-6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20-8

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Page GROUP 25 - DIFFERENTIAL

General Information ..................... . 25-1 Diagnosing Malfunctions ................. . 25-2 Removal ............................... . 25-2 Inspection and Repair ................... . 25-3 Installation and Adjustment .............. . 25-4

GROUP 30 - FINAL DRIVE (2440) General Information ..................... . 30-1 Diagnosing Malfunctions ................. . 30-2 Removal ............................... . 30-2 Repair ................................. . 30-3 Assembly ............................... . 30-4 Adjusting Axle Bearing .................. . 30-4

GROUP 32 - FINAL DRIVE (2640) General Information ..................... . 32-1 Diagnosing Malfunctions ................. . 32-2 Removal ............................... . 32-2 Inspection and Repair ................... . 32-4 Assembly ............................... . 32-4 Adjusting Axle Bearing .................. . 32-5

GROUP 35 - INDEPENDENT PTO General Information ..................... . 35-1 Testing ................................. . 35-3 Diagnosing Malfunctions ................. . 35-3 Removal and Repair .................... . 35-4

GROUP 40 - CONTINUOUS RUNNING PTO (2440)

General Information ...................... 40-1 Diagnosing Malfunctions . . . . . . . . . . . . . . . . .. 40-2 Removal and Repair . . . . . . . . . . . . . . . . . . . .. 40-2 Assembly ................... " ........... 40-8

GROUP 42 - CONTINUOUS RUNNING PTO (2640)

General Information . . . . . . . . . . . . . . . . . . . . .. 42-1 Diagnosing Malfunctions . . . . . . . . . . . . . . . . .. 42-2 Removal and Repair . . . . . . . . . . . . . . . . . . . .. 42-2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42-8

GROUP 45 - BELT PULLEY General Information ........ . . . . . . . . . . . . .. 45-1 Repair .................................. 45-1 Assembly and Adjustment . . . . . . . . . . . . . . .. 45-2


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-1 Special Tools ......................... " 50-10

I


I

50 5-14

Power Train Clutches

Repair

Separate engine from clutch housing as instructed in Section 10, Group 25 (2440) or 27 (2640).

Remove return clips (22, Fig 13) from operating levers.

Remove six cap screws (14, Fig. 13) attaching pressure plate to flywheel and lift pressure plate (29) and driven disk (4) from flywheel.

NOTE: Do not immerse clutch disk in any type of cleaning solution as solution will tend to glaze the friction surfaces.

h CAUTION: Be careful when working with .. springs under compression. Even weak

appearing springs may store enough energy to cause serious injury if released accidentally.

1-Ring Gear 2-Flywheel with Gear 3-Pilot Bearing 4-Clutch Disk

11-Clutch Fork 12-Pins 13-Carrier with Pins 14-Cap Screw 15-Washer 16-Bushing


Refer to Figure 13 for identification of parts and proceed as follows:

Remove four flywheel attaching cap screws (30) and remove flywheel (2), or use another flywheel of the same design, for repair procedures.

Place flywheel on hydraulic press for disassembling pressure assembly. Place clutch disk (4) and pressure plate assembly (29) on flywheel and alternately install three of the six attaching cap screws (14).

Use an adapter to contact inner ends of operating levers (21) and depress the operating levers as far as possible without forcing against bracket (27).

Loosen adjusting lock nuts (23) and back out the three cap screws (25) from pressure plate (28).

21-0perating Lever 22-Return Clip 23-Lock Nut 24-Washer 25-Adjusting Screw 26-Return Spring

5-Throw-out Bearing 6-Cap Screw 7-Washer 8-0il Seal 9-Packing

17-Shaft Return Spring 1B-Spring Pin 19-5haft

27-Clutch Bracket 2B-Pressure Plate 29-Pressure Plate Assembly 30-Cap Screw (4 used) 10-Bearing Carrier Support 20-Pivot Pin

Fig. 13-Single-Stage Clutch Parts

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Tractors - 2440 and 2640 TM-1142 (Mar-81)

Hydraulic System 70 General Information and Hydraulic System Tests 5-1

Section 70 HYDRAULIC SYSTEM


GROUP 05 - GENERAL INFORMATION AND HYDRAULIC SYSTEM TESTS

Page

General Information ........................ 5-2 Hydraulic System Tests ..................... 5-3

General Information ...................... 5-4 Hydraulic Oil Temperature ................ 5-4 How to Use Step-By-Step Hydraulic

Diagnosis Charts ...................... 5-4 Safety Instructions ....................... 5-5 Cross Reference Fitting Guide

for Hydraulic Flow Testing .............. 5-6 Cross Reference for Consumer

Product Test Kit ....................... 5-8 Contents of Hydraulic Diagnosis ... : ....... 5-9

GROUP 10 - MISCELLANEOUS HYDRAULIC COMPONENTS

Filter ................................... , 10-1 Oil Filter Relief Valve .................... , 10-1 Surge Relief Valve ...................... , 10-1 Inlet Line Check Valve. . . . . . . . . . . . . . . . . . .. 10-2 Pressure Control Valve ..... . . . . . . . . . . . . .. 10-2

Operation ............................. 10-2 "Hot Start" Pressure Control Valve ..... , 10-3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4

Auxiliary Oil Reservoir and Oil Cool~r ..... , 10-5

GROUP 15 - HYDRAULIC PUMPS Transmission Pump ...................... 15-1

General Information ........... . . . . . . . .. 15-1 Pump Operation ....................... 15-1 Diagnosing Malfunctions . . . . . . . . . . . . . . .. 15-1 Pump Removal ....................... , 15-2 Inspection and Repair ................. , 15-2 Installation ............................ , 15-2

Main Pump ............................. , 15-3 Operation ............................. 15-3 Diagnosing Malfunctions . . . . . . . . . . . . . . .. 15-4 Pump Removal .. . . . . . . . . . . . . . . . . . . . . .. 15-5 Inspection and Repair . . . . . . . . . . . . . . . . .. 15-5 Adjustments ............ " ............ 15-11

GROUP 20 - .. POWER STEERING General Information and Operation ........ , 20-1 Diagnosis and Tests ..................... , 20-4 Steering Valve Removal and Repair. . . . . . .. 20-4 Steering Valve Adjustment ............... , 20-8

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Page

GROUP 25 - HYDRAULIC BRAKES General Information and Operation ......... 25-1 Brake Valve Removal, Inspection, and Repair 25-2 Brake Valve and Assembly ................ 25-4 Pressure Plate, Facing, and Disks ......... 25-4 Brake Pedal Adjustment .................. 25-4

GROUP 30 - ROCKSHAFT SYSTEM General Information ...................... 30-1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30-2 Diagnosis and Tests ...................... 30-4 Removal ................................ 30-5 Inspection and Repair .................... 30-5 Load Control Mechanism. . . . . . . . . . . . . . . . .. 30-8 Assembly and Installation ................. 30-9 Adjustment ............................ , 30-11 3-Point Hitch and Quik-Coupler . . . . . . . . . .. 30-13

GROUP 35 - SELECTIVE CONTROL VALVE, BREAKAWAY COUPLER AND REMOTE CYLINDER

General Information ...................... 35-1 Selective Control Valve ................... 35-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35-2 Diagnosis and Tests .................... 35-4 Removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35-5 Inspection and Repair . . . . . . . . . . . . . . . . .. 35-6 Assembly ............................. 35-8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35-9

Breakaway Coupler. . . . . . . . . . . . . . . . . . . . .. 35-12 Remove Cylinder. . . . . . . . . . . . . . . . . . . . . . .. 35-13


General Specifications . . . . . . . . . . . . . . . . . . .. 40-1 Miscellaneous Components. . . . . . . . . . . . . . .. 40-1 Hydraulic Pumps ......................... 40-1 Power Steering .......................... 40-2 Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . .. 40-2 Rockshaft ............................... 40-3 Selective Control Valves . . . . . . . . . . . . . . . . .. 40-3 Special Tools ............................ 40-4

I



Miscellaneous 80 Front Axle 5-1

Section 80 MISCELLANEOUS


Page

GROUP 5 - FRONT AXLE General Information ........................ 5-1 Removal .................................. 5-1 Repair .................................... 5-2 Installation ................................. 5-4

GROUP 10 - FRONT AND REAR WHEELS Front Wheels

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

Rear Wheels General Information .................... 10-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4

GENERAL INFORMATION

Two types of axles are used; Regular, or Heavy Duty. Regular axles may be of the Swept-Back or Extra-Wide Straight type.

The axle assembly (consisting of front axle, knees, spindle and knuckle assembly, steering arms and bellcrank, and tie rods) pivot on the front and rear pivot pins which are pressed in the front end support and axle.

Remove the front axle assembly if new pivot pins or bushings are to be installed.

REMOVAL

Remove the front axle assembly if new pivot pins or bushings are to be installed.

Remove cotter pin and drag link nut (B), and disconnect the drag link from the steering bellcrank.

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GROUP 15 - DELUXE SEAT General Information .. . Remov~ ................... . Repair

Page

15-1 15-1

Disassembly. . . . . . . . . . . . . .. . ......... . 15-2 15-4 15-4 15-5

Inspection and Service ... . Assembly ..................... .

Installation ... .

GROUP 20 - ROLL-GARD General Information Removal ...... . Repair

Roll-Gard .... Canopy ..

Installation .................... .

GROUP 25 - SPECIFICATIONS AND SPECIAL TOOLS ...

20-1 20-1

20-2 20-2 20-3

.. 25-1

Group 5 FRONT AXLE

A-Slotted Nut B-Drag Link Nut

Fig. I-Removal Procedure

Place a metal stand or floor jack under the axle assembly to support the axle during removal.


John Deere 1840 | 2240 | 2440 | 2640 Service Manual€¦ · · 2017-11-06John Deere MODEL: 2440 &...

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Transcript of John Deere 1840 | 2240 | 2440 | 2640 Service Manual€¦ · · 2017-11-06John Deere MODEL: 2440 &...