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John Deere 4040 Troubleshooting

The John Deere 4040 is a 2WD or 4WD row crop tractor from Iron Horses series. This model was manufactured between 1978 and 1982. The John Deere 4040 tractor is powered by 404 cu.in JD 6.404D 4-cycle 6-cylinder water-cooled diesel engine with a maximum output power of 135 hp (101.5 kW) at 2200 rev/min.

The John Deere 4040 is fitted with 3 transmission options: 16x6 Quad-Range partial power shift transmission, 8x2 Syncro-Range partially synchronized transmission, or Syncro-Range creeper transmission with 13 forward and 4 reverse gears.

Max. forward speed - 19.2 mph (30.9 km/h), max. reverse speed - 11.5 mph (18.5 km/h). The closed center hydraulic system includes a piston pump with rated fluid flow of 23 gpm (87.1 lpm). The 3-point hitch has a lift capacity of 4315 lbs (1960 kg) or 5395 lbs (2450 kg). The wheel base is 104" (2640 mm).

Compatible front end loaders for the JD 4040 tractor: John Deere 148 loader with a lift capacity to max height of 3100 lbs (1406 kg), or John Deere 158 loader with a lift capacity to max height of 3800 lbs (1723 kg).

Engine Troubleshooting
Engine is not starting or hard starting
Dirty fuel filter element - Replace the filter element
The fuel shut-off valve is closed - Open fuel shut-off valve
Air trapped in fuel system - Bleed air
Faulty or dirty injectors - Check fuel injectors and replace if required
Fuel injection pump is damaged - Rebuild or replace pump
Low compression - Inspect cylinder block and change worn parts
Engine stops unexpectedly while running
Engine not warmed up - Engine is not warmed up to the required temperature
Water, dirt, or air in fuel system - Drain, flush, fill, and bleed system
Improper fuel injection - Fuel injection settings required
Fuel filter is clogged - Replace the filter element
Faulty or dirty injectors - Check fuel injectors and replace if required
Engine starts and immediately stops
Timing of fuel injection pump is wrong - Fuel injection pump timing adjustment needs to be corrected
Fuel filter is dirty - Clean or replace the filter
Damaged or clogged injector nozzles - Inspect injector nozzles and change if required
Faulty fuel injection pump - Replace injection pump or repair it
Dirty air cleaner - Change or service air cleaner element
Engine stops when idling
Low idle speed setting is not correct - Adjustment required
Defective fuel injection pump - Repair or install new pump
Fuel injector nozzles are dirty - Service or replace nozzles if required
The valve clearance is not adjusted - Need to adjust valve clearance
Engine overheating
Lack of engine coolant - Top up coolant. Check and repair damage to the cooling system if required
Cooling system parts are worn or system is clogged - Service the cooling system or change faulty parts
Engine oil level is low - Add oil to the engine crankcase
Fan belt tension is incorrect or belt is defective - Adjust belt tension correctly or change it
Thermostat malfunction - Install new thermostat
Loss of engine power
Dirty or faulty injectors - Service or change fuel injectors
Incorrect fuel injection pressure - Correct the pressure settings
Air filter element is clogged - Service or replace the air filter
Plugged engine oil filter - Service or replace engine oil filter
Engine overload - Change to lower gear or reduce load
Valve out of adjustment - Adjustment procedure required
Incorrectly adjusted low idle speed - Adjust as required
Restricted fuel hoses or pipes - Fuel pipes and hoses need to be cleaned
Low engine compression: Valves are broken or leaking - Have valves replaced
Engine noises or knocks
Timing of fuel injection pump is not adjusted - Check and correct adjustments
Fuel injector nozzles are defective or dirty - Change injector nozzles
Engine oil level is insufficient - Checking oil level and add if necessary
Engine is cold - Warm up to required temperature
Crankshaft or main bearings wear - Worn parts replacement required
Piston rings are worn or broken - Piston rings need to be replaced
Loose flywheel bolts - Inspect flywheel bolts and tighten properly
Engine using too much oil
Oil leakage: Worn gaskets or seals - Defective components must be replaced
Oil viscosity is incorrect - Use oil of proper viscosity
Worn or broken piston rings - Piston rings replacement required
Worn valve guides and valve stems - Valves need to be changed
Scuffed pistons or cylinder liners - Check liners and pistons, install new components as required

Electrical System Troubleshooting
Battery does not charge
Battery is worn - Use a new battery
Bad battery electrical wire harness - Check wires for malfunctions, repair or replace
Battery cables and terminals are loose or corroded - Tighten or clean cables and terminals
Belt is worn or belt tension is incorrectly adjusted - Adjust belt tension correctly or change belt
Starter motor cranks slow
Low battery voltage - Recharge the battery
Battery won’t hold charge - Service or change the battery
Battery electrical wire harness damage - Check battery wires for damage, replace or change
Battery terminals and cables are loose or corroded - Tighten or service terminals and cables
Starter doesn't crank
Low battery output - Battery is drained, charge it
Drained or defective battery - Replace or charge as required
Starter motor is defective - Starter needs to be changed
Incorrectly connected or disconnected wires - Check battery wires and connect correctly

Transmission Troubleshooting
Gears are hard to shift
Failure or improper clutch adjustment - Clutch replacement or adjustment required
Stuck or damaged gear shift linkage - Change or repair shift linkage
Shift forks are damaged or worn - Install new shift forks
Gearshift mechanism is worn out - Repair or replace worn components if required
Transmission oil pressure is low
Oil level is low - Fill up the transmission oil
Clogged transmission oil filter (if equipped) - Replace or clean transmission oil filter
Faulty relief valve - Install a new relief valve
Transmission makes noise
Bearings are worn or broken - Faulty bearings should be replaced
Not enough oil in transmission - Fill the transmission housing to proper oil level
Transmission oil contamination - Fill up with fresh transmission oil
Improper backlash or damaged gears - Replace gears or set backlash correctly
Shift forks are worn or damaged - Replace defective shift forks
Transmission oil leakage
Worn gaskets or seals - Replace worn seal or gaskets
Cracked transmission case - Install a new transmission case

Hydraulics Troubleshooting
Hydraulic system overheating
Improper hydraulic system pressure setting - Set the pressure properly
Main relief valve is defective or unadjusted - Adjust or replace the relief valve
Dirty hydraulic oil - The oil must be changed
Air enters in hydraulic system - Check the suction line, pump seals, and fittings
Hydraulic oil pressure is insufficient
Hydraulic fluid level is insufficient - Add fluid to the hydraulic system
Hydraulic oil filter is dirty - Service or replace the hydraulic filter
Defective hydraulic pump - Check hydraulic pump flow and replace pump if necessary
Faulty or incorrect setting hydraulic control valve - Adjust properly or replace
Hydraulic cylinder is broken - Inspect cylinder parts for wear or damage and replace if required
Leakage in hydraulic pipes - Detect leaks in the system and fix it
Hitch cannot be raised or raising is too slowly
Lack of hydraulic oil - Fill the hydraulic system with oil
Hydraulic fluid is too cold - Allow fluid to warm
Hydraulic fluid filter element is dirty - Change hydraulic filter element or clean if necessary
Hydraulic pump is defective - Test pump performance and replace pump if necessary
Defective or misadjusted main relief valve - Adjust or change relief valve
Hydraulic control valve block is faulty or out of adjustment - Replace or adjust correctly
Hydraulic cylinder is defective - Check cylinder components for damage or wear and change if necessary
Suction pipe is broken or loose - Tighten the pipe or replace it
3-point hitch won't drop or drops slowly
Damaged or incorrect adjusted hydraulic control valve - Adjust correctly or replace
Faulty hydraulic cylinder - Inspect the hydraulic cylinder components for damage or wear and change if required
Worn lift arm shaft - Install a new shaft
Damaged mechanical components of the hitch - Replace defective or worn hitch components
Three-point hitch raises or lowers not smoothly
Hydraulic system sucks air - Check the pump seals, suction pipe, and fittings
Hydraulic fluid is contaminated - Fill up with new hydraulic fluid
Hydraulic pump malfunction - Check pump flow and change pump if necessary
Hydraulic control valve is not set properly or defective - Adjust correctly or replace
Hydraulic cylinder is defective - Inspect cylinder parts for wear or damage and replace if required

Steering System Troubleshooting
Heavy steering
Steering column is defective or incorrectly installed - Steering column must be installed correctly or replaced
Air leaks in steering system - Bleed the steering system
Incorrect toe-in adjustment - Adjust toe-in correctly
Tires are deflated - Need to inflate tires
Steering pump not working - Check the steering pump and replace if necessary
Defective or worn steering valve assembly - Repair or replace the steering valve
Relief valve is seized or worn - Install a new relief valve or clean it
Not enough steering fluid - Fill up steering fluid to required level
Steering system oil leak - Retighten steering line and hose connections
Excessive steering wheel play
Steering column coupling or shaft is worn - Change faulty component
Steering valve assembly is damaged or worn - Change or repair steering valve if required
Damaged hydraulic steering pump - Repair or change steering pump
Steering linkage or tie-rod ends are defective - Replace damaged part
Tractor is pulling to right or left
Tires are not correctly inflated - Inflate tires as necessary
Toe-in adjustment is incorrect - Check toe-in and correct
Worn or faulty steering tie-rod ends or linkage - Change damaged component
Steering valve assembly is damaged or worn - Check and replace as required
Front hub bearings are worn or incorrectly adjusted - Replace or adjust the bearings correctly




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