John Deere

MODEL:

4030 Tractor Volume 1 of 2

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-TM1055

Tractor - 4030 TM-1055 (Jan-7B) 1

4030 TRACTOR TECHNICAL MANUAL

TM-1055 (JAN-78) CONTENTS

SECTION 1D-GENERAL Group 5-General Tractor Specifications Group 10-Predelivery, Delivery, and After-Sale

Services Group 15-Tune-Up Group 20-Lubrication Group 25-Separation Group 30-Specifications and Special Tools

SECTION 20-ENGINE Group 5-General Information and Diagnosis Group 10-Cylinder Head, Valve Train, and

Camshaft Group 15-Cylinder Block, Liners, Pistons, and

Rods Group 2D-Crankshaft, Main Bearings, and

Flywheel Group 25~Lubricating System Group 30-Cooling System Group 35~overnor Group 40-Specifications and Special Tools

SECTION 30-FUEL SYSTEM Group 5-Diagnosing Malfunctions Group 1D-Air Intake System Group 15-Diesel Fuel System Group 2D-Gasoline Fuel System Group 25-Speed Control Linkage Group 30-Specifications and Special Tools

SECTION 4D-ELECTRICAL SYSTEM Group 5-lnformation and Wiring Diagrams Group 10-Delcotron Charging Circuit Group 15-Delco-Remy Starting Circuit Group 2D-John Deere Starting Circuit Group 25-lgnition System Group 30-Lighting and Accessory Circuits Group 35-Specifications and Special Tools

SECTION 50-POWER TRAIN Group 5-Perma-Clutch Group 10-CreeperTransmission Group 15-Syncro-Range Transmission Group 20-Quad-Range Transmission Group 25-Differential Group 30-Final Drive Group 35-PTO, Perma-Clutch Group 40-Specifications and Special Tools

SECTION 6D-STEERING AND BRAKES Group 5-General Information

SECTION 70-HYDRAULIC SYSTEM Group 5-Generallnformation Group 6-General Hydraulic Systems Tests and

Diagnosis Group 10-Main Reservoir, Filters, Valves, and

Oil Cooler Group 15-Hydraulic Pumps Group 20-Early Model Power Steering Group 22-Late Model Power Steering Group 25-Power Brakes Group 30-Rockshaft Group 35-Selective Control Valve, Breakaway

Couplers, and Remote Cylinders Group 40-Specifications and Special Tools

SECTION SD-MISCELLANEOUS Group 5-Front Axles Group 10-Air Conditioning System Group 15-Heating System Group 2D-Specifications and Special Tools

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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30 Fuel Systems 20-8 Gasoline Fuel System

Fig. 1~Removing Fuel Valve Needle

Fig. 1B-Thrott/e Shaft & Valve

Remove throttle valve screws, t~rottle valve (Fig. 18), then remove throttle shaft from throttle body.

Using a small screwdriver or punch, remove the throttle shaft packing, and retainer (Fig. 11, items 6 and 7).

Remove throttle shaft needle bearings (Fig. 11, item 8), in the same manner instructed for re­moving the throttle shaft retainer.

Remove the discharge nozzle (Fig. 17) from the fuel bowl. Using a screwdriver, remove the power jet (Fig. 11, item 25) from opening created by the removal of the discharge jet.

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Tractor - 4030 TM-1055 (Jan-7B)

Fig. 17-Removing Nozzle and Jets

Fig. 18-Choke Assembly and Solenoid

Close choke and mark across the air intake body, choke brackets (Fig. 18), and choke lever as a guide to aid in the correct assembly of parts.

Remove the choke disk screws and choke disk from inside air intake housing.

Remove choke shaft and bracket from side of air intake housing.

40 6-26

Electrical System Electrical System Diagnosis

Step Sequence

@ 1. Starting aid will not flow starting fluid.

2. Engine cranks but stops cranking when starting aid switch is pushed "IN".

@ The John Deere NO starter is used in steps where a starter is shown. Review tractor model and type of starter equipped for differences in lead and terminal locations.

JOHN DEERE ND DELCOREMV

Starter Circuit --+...{()Ji.:)r---{ Relay

The following STARTING CIRCUIT problems will direct you to the DIAGNOSING SEQUENCE for that problem:

Result

Tractor - 4030 TM-1055 (Jul-79)

GO TO H1

GO TO J1

NOTE: The following starting circuit sequence applies only to tractors including and above the following serial numbers (or) if an electric starting aid kit has been field installed on tractors prior to the following serial numbers:

4030 - 007000 4230 - 013000 4430 - 017500 4630 - 007000

GO TO A6

1. Starter operates, but engine does not crank.- - -- -- - - _____ j......::G:.0=-T:..;0:....:B:..;1:...-~ 2. Starter .solenoid chatters, (engine mayor may not crank). - - -- -- -- - - &....;G::.0=-T;..;0=--=C:..;1~ ..... 3. Starter solenoid does not operate with transmission in

"PARK". - - - - -- - - - - - - - - -- - - - - - I-.,.:G:.,::0:...T.:..;:0::...:::.D..:..1---1 4. Engine cranks slowly-. - - - - - - - - - - - - - - __ - _a......;G==0~T:..;0=-=E~1_-I 5. Engine cranks in gear.- - - - - - - - - - - - - - - - - -L-G==0~T.;..0:....;F...;1~ .... 6. Starter continues to operate after engine starts or

after fuel shut-off pulled out. ----------.:...- -----__ 1 GO TO G1

@ PROBLEM:

Starter Operates, But Engine Does Not Crank.

R33612

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Remove starter to inspect: Repair, then ... (GO TO A1 1. Flywheel ring gear. 2. Overrunning clutch drive. 3. Shift mechanism. 4. Solenoid plunger linkage. 5. Broken armature shaft.

Tractor - 4030 TM-1055 (Jan-78)

Electrical System Defco-Remy Starting Circuit

Group 15 DELCO ... REMY STARTING RCUIT

GENERAL INFORMATION NOTE: See Group 20 for John Deere Starting

Circuit.

The Delco-Remy starting circuit consists of the battery, Delco-Remy starter with solenoid switch, starter circuit relay, key switch, start-safety switch, and connecting wires or cables. The starter has a totally enclosed shift lever and an overrunning clutch.

When the transmission is in neutral or park, the start-safety switch is closed so the starter can be operated.

When making tests, the battery voltage should not drop below 9 volts. Never overheat the starter.

DIAGNOSIS AND Place the transmission in PARK. Turn the key

switch on. The tractor voltmeter should indicate battery voltage. If it does, then turn the key switch to start the engine.

Voltmeter Fails to Read Battery Voltage

Defective key switch Defective wiring from battery to key switch

Solenoid Switch Chatters

Discharged battery Poor connection (usually at battery, starter, or

starter circuit relay) Open in solenoid hold-in circuit

Sluggish Starter Operation

Discharged battery High resistance in circuit Excessive engine drag Defective starter

If starter does not operate, connect a voltmeter to the solenoid "S" terminal and a good ground.

Voltmeter Indicates Betlery Voltage

Defective st.arter Defective starter solenoid switch

Voltmeter Does Not Indicate Battery Voltage Starter circuit relay not operating Defective starter circuit relay Defective wiring between battery, starter circuit

relay, and solenoid "S" terminal

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Starter Circuit Relay Does Not Operate Defective key switch Defective start-safety switch Maladjusted start-safety switch Missing start-safety switch cam follower (see

Section 50) Defective wiring between battery and starter

circuit relay

High Resistance Test To prevent the engine from running when mak­

ing tests, hold the diesel engine stop knob out or, on a gasoline engine, disconnect and ground the distributor end of the coil high-tension wire.

Connect voltmeter to ground and to solenoid battery terminal. Operate starter and compare volt­age with a similar reading at battery. Use a pin connector at battery post. If difference is more than 0.8 volt, make tests shown in Fig. 1 or 2 to locate defective wire or faulty connection.

R 21897 N

+

Fig. 1 - Resistance Test for Tractors Without Electric Ether Aid

STARTER CIRCUIT

RELAY

START­SAFETY SW I TCH

R 21900N

Fig. 2 - Resistance Test for Tractors With Electric Ether Aid

A-G, B-C, C-E, or C-F . . . . . . . . . . . . . . . .. 0.2 C-D ................................ 1.0

Tractor - 4030 TM-1055 (Jul-79)

Electrical System 40 Specifications and Special Tools 35-7

SPECIAL TOOLS

No. Name Use

Charging Circuit

A200JO· .................. Alternator service tool seL .............................................................. To service alternator 7004' ...................... Alternator pulley nut remover ............................................ To remove alternator pulley nut JOST-2B· ................. Belt tension gauge ....................................................................... To measure belt tension

Starting Circuit

JOE-BO' ................... Starter wrench ........................................ To remove and install starter mounting stud nut ................... Prelubricated bushing arbor"' .......................... To Install overrunning clutch bushings or

commutator end frame bushing in Oelco-Remy starters ................... Bushing arbors' • • ........................................... To install bushings in John Oeere starters ................... Pole shoe screw driver ..................................................................... To remove field coils ................... Commutator turning tool. ...................................................................... To turn commutator ................... Armature tester ..................................... To check armature for shorts, grounds, or opens ................... Spring tension gauge ......................................................... To check brush spring tension

Lighting and Accessory Circuit

JOST-33· ................. Universal Gauge Tester ............................................ To test gauges in instrument cluster

'Order from Service Tools, Box 314, Owatonna, Minnesota 55060 • ·See "Making Special Tools" on page 40-15-7.

• • • See "Making Special Tools" on page 40-20-7.

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Tractor - 4030 TM-1055 (Jan-78)

Power Train 50 Perma-Clutch 5-1

Section 50

WER TRAIN CONTENTS OF THIS SECTION

Page

GROUP 5-PERMA-CLUTCH General Information .................. 5-2 Diagnosing Malfunctions .............. 5-8 Testing ............................. 5-8 Shafts and Controls

Removal .......................... 5-10 Repair ........................... 5-12 Assembly ......................... 5-12 Adjustments ...................... 5-13

Clutch Assembly Removal ......................... 5-14 Repair ........................... 5-14 Assembly ......................... 5-15 Adjustment ....................... 5-16

GROUP 10-CREEPER TRANSMISSION General Information .................. 10-1 Creeper Planetary

Diagnosing Malfuntcions ............ 10-3 Removal .......................... 10-3 Assembly ......................... 10-5

Eight-Speed Transmission Diagnosing Malfunctions ............ 10-7 Removal .......................... 10-7 Repai r ........................... 10-8 Installation ....................... 10-11 Adjustment ....................... 10-13

GROUP 15-SYNCRO-RANGE TRANSMISSION General Information ................. 15-1 Diagnosing Malfunctions .............. 15-2 Removal ............................ 15-2 Repai r ............................. 15-4 Installation .......................... 15-6 Adjustment ......................... 15-9

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Page

GROUP 20-QUAD-RANGE TRANSMISSION General Information .................... 20-1 Diagnosing Malfunctions ................ 20-5 Testing ................................ 20-6 Two-Speed Power Shift Planetary

Removal ............................. 20-7 Assembly and Installation ............. 20-10

Eight-Speed Transmission Removal ............................. 20-11 Repair ............................... 20-13 Assembly ............................ 20-14

Range and Speed Selector Assembly Removal ............................. 20-17 Assembly and Adjustment ............. 20-17

GROUP 25-DIFFERENTIAL General Information ................... 25-1 Removal ............................. 25-1 Repai r ............................... 25-2 Assembly ............................ 25-3 Adjustment ........................... 25-3 Lock Valve Test and Adjustment ......... 25-4

GROUP 30-FINAL DRIVE Removal ............................. 30-1 Assembly ............................ 30-1 Installation ........................... 30-2

GROUP 35-PTO, PERMA-CLUTCH General Information ................... 35-1 Diagnosing Malfunctions ............... 35-1 Removal ............................. 35-1

GROUP 40-SPECIFICATIONS AND SPECIAL TOOLS

Specifications .......................... 40-1 Special Tools .......................... 40-9

50 Power Train 5-2 Perma-Clutch

Group 5 PERMA-CLUTCH

GENERAL INFORMATION The Perma-Clutch is standard with all Syncro­

Range and Quad-Range transmissions.

The transmission and PTO clutch assemblies (Fig. 4) each consist of two oil cooled disks, with mechanical engaging levers operated by an an­nular hydraulic piston and needle thrust bearing. The front clutch supplies engine power to the transmission and the rear clutch supplies engine power to the PTO. The clutches operate indepen­dently of each other.

The transmission clutch is controlled by a clutch pedal-operated valve and the PTO clutch is con­trolled by PTO lever-operated valve. Pressure oil to engage the operating pistons is provided by an oil pump mounted at the rear of the transmission drive shaft. The pump is driven by a hex. shaft from the flywheel and therefore provides pressure whenever the engine is running.

The pump also forces oil under pressure through the transmission and clutch shafts to cool and lubricate the clutch and transmission. For service information on the transmission oil pump, see Sec­tion 70, Group 15. For information on lubrication oil flow, see Fig. 5.

Cooling oil for the clutches is returned to the transmission by means of a cast opening in the upper portion of the clutch housing. Oil which col­lects in the bottom of the clutch housing is thrown up into the cast opening by the rotating clutch and flywheel.

Transmission Clutch Valve The transmission clutch valve is located in the

clutch valve housing, which is fastened to the in­side of the pressure regulating valve housing. The pressure regulating valve housing is attached to the left-hand side of the clutch housing.

The operating arm shaft (Fig. 1), is held in the engaged position by the clutch pedal return spring. Oil at system pressure (110 psi) is routed to the clutch operating piston to engage the transmission clutch. Note that pressure oil is also routed to the bottom of the valve to counteract the upper spring which is pushing the valve down.

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TO CLUTCH

R 19488

Tractor - 4030 TM-1055 (Jan-78)

OPERATING ARM SHAFT

SYSTEM PRESSURE

CLUTCH PRESSURE

UPPER SPRING

LOWER SPRING

LUBE 0 I L

PRESSURE FREE OIL

Fig. 1-Clutch Valve Engaged

The oil pressure at the bottom of the valve pro-' vides modulation during engagement. As the valve land uncovers the clutch pressure passage, the pressure oil also acts on the valve, opposing spring pressure to prevent sudden clutch engagement. Modulation is accomplished first by the lower spring. When the spacer pin bottoms in the valve, modulation is provided by the stiffer upper spring. The clutch valve is forced fully open by the upper spring being compressed solid as the arm com­pletes its downward travel.

When the clutch is disengaged, the operating arm rotates upward pulling the valve up by the cross-pin pressed into the valve. The valve then cuts off system pressure and opens the clutch pressure passage to sump. The clutch pressure plate return springs (26, Fig. 4) return the operating bearing (18) to the disengaged position by way of the clutch operating levers.

PTO Clutch Valve and Lock Piston The PTO clutch valve and lock piston are in the

same housing as the transmission clutch valve.

50 Power Train 5-4 Perma-Clutch

R21625N

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_ LUBE OIL

Fig. 4-Perma-Clutch and PTO Drive

Tractor - 4030 TM-1055 (Jan-7B)

Tractor - 4030 TM-1055 (Jan-78)

If the differential drive shaft must be replaced, the differential ring gear must also be replaced. The ring gear and drive shaft are supplied as a matched set. Use both new parts when replacing either. See Group 25 of this section for further instructions. Repair and removal of the differential are also covered in Group 25 of this section.

The console must be disassembled to remove the shift lever. Remove the six cap screws holding the sheet metal around the console and the three cap screws under the right wheel fender.

Remove load control selector lever knob and re­move sheet metal.

Remove cap screws holding selective control valve levers and remove levers through top of lever guide. Remove cap screw on rockshaft control lever and remove lever.

Remove lever guide over shift lever.

Fig. 11-Throttle Control Lever Assembly

Disconnect speed control rod. Remove cap screw on throttle control lever (Fig. 11) and remove throttle control lever.

Remove cotter keys and pins from shift control shafts. Remove collar and cap screw (Fig. 12). Re­move quadrant bracket and quadrant. Remove shifter control arm.

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Power Train 50 Syncro-Range Transmission 15-5

Fig. 12-Quadrant and Control Lever

Fig. 13-Removing Spring Pins

If the shift lever or pivot must be replaced, place shift lever assembly in a vise and slip a 5/32-inch cotter pin inside each of the spring pins (Fig. 13).

50 Power Train 2()"12 Quad-Range Transmission

NOTE: If only the transmission drive shaft re­quires service, this can be accomplished by work­ing through the clutch housing.

Remove pawl retainers before attempting to re­move shifter shaft and shifters. The retainers are spring loaded so exercise caution.

Fig. 22-Speed Shifters and Cam

Lower shifter arm to place speed shifter cam (Fig. 22) in its lowest position. Remove nut and cam shaft. Avoid damaging oil seal. Rotate shifters up­ward to remove them.

Fig. 23-Transmission Oil Pump and Tubes

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Tractor - 4030 TM-1055 (Jan-7B)

Remove the transmission oil pump manifold, inlet and outlet tubes, and pump (Fig. 23). Use a brass drift to drive transmission drive shaft and rear bearing cup rearward for shaft removal. Tape or clip the synchronizers together so they will not separate during removal of the shaft.

It is necessary to remove the differential from the tractor for differential drive shaft removal. See Group 25 of this section.

To remove differential drive shaft, first remove plate on end of shaft.

Fig. 24-Pulling Front Bearing Cone

After differential has been removed, install a "C" clamp (Fig. 24) through hole in transmission case to hold C-Range gear forward against case. Use a soft hammer to drive the differential drive shaft to the rear. Continue to drive the shaft and tighten the clamp until front bearing cone is free.

80 Miscellaneous 10·12 Air Conditioning System

FitJ. 12-Removing Hub and Drive Plate

Fig. 13-Removing Retaining Ring and Spacer

5. Remove hub drive key from shaft.

Installing Compressor Hub and Drive Plate Assembly

1. Place drive key in hub drive plate. Position key

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Tractor - 4030 TM-1055 (Jan-78)

so that it will protrude 3/16 inch from shoulder of s_haft when installed (Fig. 14).

Fig. 14-Drive Key Position

2. Align hub and drive plate assembly with key in shaft. Position assembly in compressor front end casting.

IMPORTANT: Do not drive or pound on hub of drive plate assembly or on end of compressor shaft. Use the proper tools to prevent possible shifting of swash plate position (keyed to main shaft), thereby causing compressor damage.

Fig. 15-1nstalling Hub and Drive Plate