John Deere MODEL: SIn 0-349,999 JD-S-TM4301

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1 John Deere MODEL: 2240 SIn 0-349,999 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-TM4301

2 Tractor 2240 Technical Manual GENERAL 10 ENGINE 20 FUEL SYSTEM 30 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. ELECTRICAL SYSTEM 40 POWER TRAIN 50 STEERING AND BRAKES 60 HYDRAULIC SYSTEM DEERE & COMPANY MOline, Illinois All rights reserved MISCELLANEOUS 80

3 TM-4301 (Feb-79) General Section 10 GENERAL GROUP 5 - SPECIFICATIONS Serial numbers Model numbers Engine Engine clutch Electrical system Transmission Hi-Lo shift unit... Differential and final drives Differential lock... PTO.... Hydraulic system Power steering Manual steering Hydraulic brakes Capacities Travel speeds.. Front and rear wheels Dimensions and weights GROUP 10 - PREDELIVERY, DELIVERY AND AFTER-SALES INSPEC TIONS Predelivery inspection Delivery inspection After-sales inspection. 5-3 GROUP 15 - LUBRICATION AND PERIODIC SERVICE Lubrication and periodic service GROUP 20 - ENGINE AND TRACTOR TUNE-UP Preliminary engine testing Engine tune-up.... Checking engine performance Tractor tune up.... Standard torques.... GROUP 25 - TRACTOR SEPARATION Separating between engine and tractor front end.... Removing and installing engine and installation of clutch housing... and installation of final drives.... and installation of rockshaft... Special tools

4 TM-4301 (Feb-79) General Information TRANSMISSION Type Gear selections Shifting HI-LO SHIFT UNIT Collar shift 8 forward and 4 reverse 4 speeds each in high, low, and reverse ranges. Park lock included. Hydraulically controlled reduction gear which can be shifted under load, with "wet" multiple disk clutch and "wet" multiple disk brake. Allows reduction of the individual gear speeds by 21 %. DIFFERENTIAL AND FINAL DRIVES Planetary reduction gear and differential with spiral bevel gears. DIFFERENTIAL LOCK Hand or foot operated; spring-loaded out of engagement. PTO Type... Rear 540 rpm continuous-running or independent Power Shaft Speeds HYDRAULIC SYSTEM Closed center, constant pressure system; also includes rockshaft, power steering and selective control valves. Stand by oil pressure to kpa (153 to 157 bar) (2220 to 2280 psi) Pump piston pump driven by the engine POWER STEERING The steering. system is a "closed center" type incorporated by the hydraulic system and supplied with oil by the hydraulic pump. It is connected to the front wheels by means of a steering linkage. MANUAL STEERING The manual steering is a recirculating ball bearing, worm and nut type. A number of steel balls between ball nut and steering wheel shaft provide for positive engagement of steering wheel and steering linkage. HYDRAULIC BRAKES The disk brakes run in an oil bath and are hydraulically controlled. CAPACITIES Fuel tank... Cooling system. Ltr US.gals Engine Speed in rpm PTO shaft speed in rpm Engine crankcase incl. filter..... Transmission-hydraulic system Dry system... At service intervals Belt pulley TRA VEL SPEEDS See Operator's Manual FRONT AND REAR WHEELS For tire sizes, treads, inflation pressure and weights see Operator's Manual. DIMENSIONS AND WEIGHTS See Operator's Manual.

5 General 10 Tractor Separation 25-3 Make sure transfer pump inlet line is behind and below fuel pressure line. Open fuel tank shut-off valve. Connect cable to fuel gauge sending unit and to air cleaner restriction warning switch. Lift and slide radiator into location from the left side of tractor. Slide fan shroud forward over radiator and secure with screws. Secure radiator to front axle support. Install upper and lower water hoses. Only on tractors equipped with oil cooler: Connect hose elbow between hydraulic oil reservoir and oil cooler at top of oil cooler and return line at bottom of oil cooler. Only on tractors not equipped with oil cooler: Connect oil line to oil reservoir and tighten both hose clamps. Connect leak-off and bleed lines to hydraulic reservoir. Connect hydraulic pump pressure line and install line spacers and clamps (see fig. 2). Connect air intake pipe at manifold and air cleaner. Attach drag link to bell crank and tighten slotted nut to specified torque. Install hood and radiator side grille screens. Fill radiator with clear, soft water, adding an antifreeze and rust inhibitor mixture (see operator's manual). Connect battery ground straps. IMPORTANT: Always connect ground straps to negative(-) pole of batteries. Start engine and check fuel lines, hydraulic lines and water hoses for leaks. NOTE: For most engine service operations the engine need not be removed. However, if the crankshaft has to be removed or in case of major overhaul, remove engine. REMOVAL For safety disconnect ground straps from batteries. Separate tractor front end from engine, as explained previously. Disconnect cables between alternator and regulator by removing three-terminal plug at alternator. Disconnect red cable at terminal B+ of alternator. REMOVING AND INSTALLING ENGINE Disconnect all cables 4 at starting motor (see fig. 4). Disconnect oil pressure warning switch cable 3. Disconnect flexible shaft 2 of speed-hour meter at clutch housing and camshaft. If necessary, replace gasket. Fig. 4 - Separating between Engine and Clutch Housing, R.H. Side 1 Engine attaching points 2 Flexible shaft of speed-hour meter 3 Oil pressure warning switch 4 Starter cables Litho in U.8.A.

6 Engine General Infotmation, Diagnosing Malfunctions GROUP 10 - CYLINDER HEAD AND CAM SHAFT Gen~ral information Cylind~r head... Adjusting valve clearance Camshaft.. Installa tio n Sp~cial tools GROUP 15 - CYLINDER BLOCK, LINERS, PISTONS AND CONNECTING RODS RemQval.. 15"1 Repa~r.... Assembly Torq~es for hardware 15-8 Engine preak-in 15-9 Tune-up data 15-9 Special tools GROUP 20 - CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL SpecifiCations Special tools Section 20 ENGINE GROUp 5 - GENERAL INFORMATION, DIAG NOSING MALFUNCTIONS GROUP 25 - TIMING GEAR TRAIN Diagnosing malfunctions Special tools GROUP 30 - ENGINE LUBRICATION SYSTEM Oilpump Oil pressure regulating valve 30-2 Oil cooler Oil pump Oil pressure regulating valve 30-4 Oil cool~r. ' 30-4 Oilfilter Oilpump Oil pressure regulating valve Oil cooler Oil filter Adjusting engine oil pressure Special tools GROUP 35 -, COOLING SYSTEM... Diagnosing malfunctions. Radiator Adjusting fan belt Water pump..'. Checking thermostat..... Special tools GROUP 40 - SPEED CONTROL LINKAGE... and disassembly.... Assembly and installation Adjusting speed control linkage

7 Fuel System Diagnosing Malfunctions Section 30 FUEL SYSTEM GROUP 5 - DIAGNOSING MALFUNCTIONS Diagnosing malfunctions GROUP 10 - FUEL TANK, FUEL TRANSFER PUMP AND AIR CLEANER Fuel tank Fuel transfer pump Diagnosing malfunctions Fuel filter.. Dry-type air cleaner.. Inspecting air intake system GROUP 15 - ROTO DIESEL INJECTION PUMP.... and adjustment... GROUP 20 - INJECTION NOZZLES Diagnosing malfunctions Repail Special tools GROUP COLD WEATHER STARTING AID

8 30 Fuel System 20-2 Fuel Injection Nozzles Tractor-2240 REMOVAL REMOVING ONE OR SEVERAL INJECTION NOZZLES IMPORTANT NOTES Before removal, carefully remove all dirt from the cylillder head around injection nozzles and blow off with compressed air in order to prevent any dirt entering the cylinders or valve seats. Plug the bore in the cylinder head after injection nozzle has been removed. Cap fuel line openings as soon as they are removed. Fit protectillg caps immediately over the nozzle tip and the lille connection to avoid damage to the nozzle when handling it. Do not bend the fuel pressure lines, as this may affect their durability and breakdowns may occur. When loosenillg the fuel pressure line, hold male union of nozzle line. 1. Remove hood (see Operator's Manual). Fig. 3 - of Injection Nozzle by Hand 4. Remove cap screw 25 (fig. 2) from cylinder head and pull complete injection nozzle from cylinder head by hand (see fig. 3). Should this not be possible because the nozzle is "set" in the cylinder head with carbon deposits, then use special puller No. JDE 38 (see fig. 4) A Fig. 2 - Injection Nozzle Installed 15 Locating clamp 19 Union nut 20 Fuel leak-off cap 21 Hex. nut 24 Spring clamps 25 Cap screw 26 Spacer ring 2. Withdraw leak-off hoses from leak-off caps 20 (fig. 2) of injection nozzles to be removed. Turn hex. nut 21 off cap 20. Remove cap and withdraw hex. nut 21 with grommet 22 (see fig. 1) from nozzle. 3. Unscrew union nut 19 (fig. 1 and 2) from male union 16 (fig. 1), holding the latter firmly with a wrench. Fig. 4 - of Injection Nozzle with Special Puller No. JDE 38

9 Electrical System Diagnosing Malfunctions Section 40 ELECTRICAL SYSTEM GROUP 5 - DIAGNOSING MALFUNCTIONS GROUP 15 - STARTING MOTOR Batteries.... Alternator.... Tests and diagnosis on tractor Starting motor. Controls.. Head lights GROUP 10 - COMPONENTS AND WIRING DIAGRAM Disassem bly Assembly. Lubrication instructions before and during assembly GROUP ALTERNATOR AND REGULATOR Important Notes General Information System.... Batteries.... Controls and Instruments Cables and Wires Wiring Diagram... Torques for Hardware Alternator.... Disassembly Testing and repair Assembly. Output test Regulator.. Special tools I

10 TM-4301 (Feb-79) Power Train 50 Engine Clutches and Clutch Linkage 5-1 GROUP 5 - ENGINE CLUTCHES AND CLUTCH LINKAGE Diagnosing malfunctions Single-stage clutch (independent PTO) Clutch linkage Clutch : 5-4, Disassembly and Assembly and adjustment Linkage adjustment Single-stage clutch (reverser) Assembly and adjustment Dual-stage clutch (continuous PTO) Clutch linkage and adjustment Clutch and disassembly and assembly Adjustment and adjustment Clutch housing Drive shafts Special tools GROUP 10-HI-LO SHIFT UNIT Checking operating pressure Diagnosing malfunctions Disassembly Assembly Special tool GROUP 15 - COLLAR-SHIFT TRANSMISSION Diagnosing malfunctions Shifter mechanism Transmission shafts and gears GROUP 20 - Section 50 POWER TRAIN DIFFERENTIAL Diagnosing malfunctions Adjustment GROUP 25 - FINAL DRIVES Diagnosing malfunctions Adjustment GROUP 30 - CONTINUOUS-RUNNING PTO GROUP 35 - INDEPENDENT PTO Diagnosing malfunctions Operation Testing oil pressure PTO shaft assembly PTO clutch PTO brake Control valve assembly Special tool GROUP 40 - REVERSER Testing Diagnosing malfunctions Adjustments Litho in UoSoA.

11 Front Axle, Steering System and Brakes Front Axle Section 60 FRONT AXLE, STEERING SYSTEM AND BRAKES GROUP 5 - FRONT AXLE Ihstallation and adjustment Special tool Assembly. Adjustment Special tools GROUP 15 - HYDRAULIC BRAKES GROUP 10 - STEERING SYSTEM Power Steering Operation.... Testing steering system Diagnosing malfunctions.... Assembly.... and adjustment Manual Steering Diagnosing malfunctions Brake valve Adjustment and bleeding Pressure rings and brake disks

12 Hydraulic System General Information, Diagnosing Malfunctions and Tests GROUP 5 - GENERAL INFORMATION, DIAG NOSING MALFUNCTIONS AND TESTS Operation. Diagnosing malfunctions Tests.... General hydraulic system testing System leakage test.... Time cycle tests Pressure tests Transmission oil pump test Hydraulic pump tests... Rockshaft tests Selective control valve tests Special tools.... GROUP 10 - OIL RESERVOIR, FILTER, VALVES AND OIL COOLER Main oil reservoir, transmission oil filter and intake screen.... By-pass valve of transmission oil filter.... Surge relief valve in clutch housing.... Check valve in inlet line to hydraulic pump (tractors without Hi-Lo shift unit or independent PTO) Pressure control valve of power steering Assembly.... Auxiliary oil reservoir Oil cooler.... GROUP 15 - HYDRAULIC PUMP AND TRANSMISSION OIL PUMP Hydraulic pump Section 70 HYDRAULIC SYSTEM Adjustment Transmission oil pump ' Special tools GROUP 20 - ROCKSHAFT.... Assembly.... Adjustment..... Load control mechanism.. Adjustment Three-point hitch Spe.cifications Adjustments... Special tool GROUP 25 - SELECTIVE CONTROL VALVE AND BREAKAWAY COUPLER Selective control valve Diagnosing malfunctions. Operation Adjustment..... Breakaway coupler..... Special tools..... GROUP 30 - REMOTE CYLINDER Bleeding

13 Miscellaneous Belt Pulley Section 80 MISCELLANEOUS GROUP 5 - BELT PULLEY GROUP 15 - FRONT AND REAR WHEELS and disassembly... _... Assembly and adjustment... GROUP 10 -OPERATOR'S SEATS DE LUXE seat... Standard seat Front wheels.... Adjusting front wheel bearings Rear wheels (tractors with rack-and-pinion axle) Group 5 BELT PULLEY GENERAL INFORMATION The belt pulley assembly is driven by the PTO stub shaft. It is a straight bevel gear type unit and is attached to the transmission case. REMOVAL AND DISASSEMBLY Drain oil from pulley case by removing filler plug. Remove pulley guard. Remove pulley from shaft, using a puller if necessary.

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