John Deere Tractors 76F, 85F, 100F Diagnostic & Repair Servicve Technical Manual (TM103319)
Complete Diagnosis Operation Tests Repair Service manual for John Deere Tractors 76F, 85F, 100F, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere Specialty Tractors 76F, 85F and 100F workshop John Deere Tractors 76F, 85F, 100F manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM103319 TM - All Inclusive 76F, 85F and 100F Tractors (North American Edition).pdf
TM103363 TM - All Inclusive Manual técnico de diagnóstico y reparación de tractores 76F, 85F y 100F.pdf
PRODUCT DETAILS:
Total Pages: 1,443 pages
File Format: PDF
Language: English Spanish
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MAIN SECTIONS
Foreword
General Information
Safety
General Specifications
Fuel and Lubricants
Serial Number Locations
Features and Accessories
Engine Repair
Engine
Cylinder Head and Valves
Cyl. Block, Liners, Pistons and Rods
Crankshaft, Main Bearings and Flywheel
Camshaft and Timing Gear Train
Lubrication System
Cooling System
Fuel and Air Repair
Fuel System
Air Intake and Exhaust System
Speed Control Linkage
Electrical Repair
Battery, Starter and Alternator
Electrical System Components
Wiring Harness
Power Train Repair
Clutch Housing
Clutch Assembly
Transmission
Rear PTO Drive Shaft
Differential
Final Drives
Mechanical Front Wheel Drive
Steering and Brake Repair
Steering Repair
Brake Repair
Hydraulic Repair
Hydraulic Pump and Filter
Rockshaft (85F, 100F)
Rockshaft (76F)
Selective Control Valve (SCV)
Miscellaneous Repair
Wheels
3-Point Hitch
Operator Station Repair
Seat and Support
Roll-GardROLL-GARD is a trademark of Deere & Company.
Operator Platform
Fenders
Air Conditioning System
Operator’s Cab
Operational Checkout Procedures
Operational Checkout Procedures
Engine Operation, Tests and Adjustments
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Fuel/Air Operation, Test and Adjustments
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Electrical System Operation, Tests and Adjust
Operation and Tests-General
SE01-Starting System
SE02-Charging System
SE03-Instrument Panel
SE04-Lighting System
SE05-Turn Signal and Hazard Warning Lights
SE06-Horn
SE08-Parking Brake
SE10-Rear PTO Warning System
SE11-Front Wheel Drive
SE12-7-Pin Connector for Trailer Lights
Component Information-Connectors
Component Information-Wiring Harnesses
Component Information-Electrical Parts
Component Information-Ground Connections
Wiring Diagrams
Power Train Operation, Tests and Adjustments
Component Location-Transmission
Theory of Operation-Transmission
Diagnosis, Tests, and Adjustments-Transmission
Steering and Brake Operation, Test & Adjustments
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Hydraulic System Operation, Test and Adjustments
Component Location
Theory of Operation
Diagnosis
Hydraulic Tests
Adjustments
Hydraulic Schematics
Air Conditioning System-Operation and Tests
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Special Tools
Special Tools (Available as Spare Parts)
TABLE OF CONTENTS................1
Section 10: General Information................1357
Group 05: Safety................30
Recognize Safety Information................33
Understand Signal Words................34
Follow Safety Instructions................35
Handle Fuel Safely—Avoid Fires................36
Prevent Battery Explosions................37
Prepare for Emergencies................38
Prevent Acid Burns................39
Service Cooling System Safely................41
Avoid High-Pressure Fluids................42
Park Machine Safely................43
Support Machine Properly................44
Wear Protective Clothing................45
Work in Clean Area................46
Work In Ventilated Area................47
Illuminate Work Area Safely................48
Replace Safety Signs................49
Use Proper Lifting Equipment................50
Service Tires Safely................51
Avoid Harmful Asbestos Dust................52
Avoid Heating Near Pressurized Fluid Lines................53
Remove Paint Before Welding or Heating................54
Use Proper Tools................55
Dispose of Waste Properly................56
Live With Safety................57
Group 10: General Specifications................851
Summary of References—General Specifications................851
Machine Specifications................851
Repair Specifications................851
Ground Speed Estimates................66
Service Recommendations for O-Ring Boss Fittings................68
Service Recommendations for Flat Face O-Ring Seal Fittings................70
Metric Bolt and Cap Screw Torque Values................72
Unified Inch Bolt and Cap Screw Torque Values................73
Group 15: Fuel and Lubricants................31
Summary of References—Fuel and Lubricants................76
Diesel Fuel................77
Bio-Diesel Fuel................78
Handling and Storing Diesel Fuel................79
Fuel Storage................80
Do Not Use Galvanized Containers................81
Fill Fuel Tank................82
Diesel Engine Oil................83
Diesel Engine Coolant................85
Transmission and Hydraulic Oil................87
Grease (Specific Application)................88
Grease................89
Alternative and Synthetic Lubricants................90
Lubricant Storage................91
Group 20: Serial Number Locations................31
Summary of References—Serial Number Locations................93
Serial Numbers................94
Product Identification Number Location................95
Engine Serial Number Location................96
Fuel Injection Pump Serial Number Location................97
Alternator Serial Number Location................98
Record Cab Serial Number................99
Group 25: Features and Accessories................102
Summary of References—Features and Accessories................102
Features and Accessories................102
Standard Features................103
Field Installed Optional Kits and Accessories................105
Section 20: Engine Repair................106
Group 05: Engine................106
Summary of References—Engine................112
Service Equipment and Tools................603
Specifications................851
Remove Engine................115
Install Engine................121
Engine Disassembly Sequence................127
Sealant Application Guidelines................129
Engine Re-Assembly Sequence................130
Engine Break-In Guidelines................132
Perform Engine Break-In................133
Diesel Engine Break-In Oil................134
Group 10: Cylinder Head and Valves................106
Summary of References—Cylinder Head and valves................136
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Cylinder Head - Exploded View................143
Check Valve Lift................144
Remove Cylinder Head................146
Clean Injection Nozzle Bores................150
Inspect and Clean Cylinder Head................151
Valve Actuating Parts................152
Remove Valves and Valve Springs................153
Measure Cylinder Head Thickness................154
Clean Valve Guides................155
Measure Valve Guides................156
Clean and Inspect Valve Seats................158
Lapping Valve Seats................159
Check Valve Recess................160
Remove Valve Seat Inserts................161
Check Valves................163
Grind Valves................164
Check Valve Spring Compression................165
Install Valves................166
Install Cylinder Head................168
Torque Turn Tightening Method................171
Disassembly and Checking—Rocker Arm Shaft................173
Assembly—Rocker Arm Shaft................175
Install Rocker Arm Assembly................177
Valve Clearance................179
Install Rocker Arm Cover................180
Final Work................182
Group 15: Cyl. Block, Liners, Pistons and Rods................107
Summary of References—Cyl. Block, Liners, Pistons and Rods................184
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Cylinder Block—Exploded View................191
Connecting Rods - General Information................1357
Remove Pistons and Connecting Rods................194
Measure Cylinder Liner Bore................197
Remove Cylinder Liners................198
Cylinder Liner Deglazing................199
Cylinder Blocks Cleaning................200
Measure Camshaft Bore................201
Measure Crankshaft Bore................202
Measure Cylinder Liner Protrusion................203
Liner Shim Installation................205
Install Cylinder Liners................206
Measure Connecting Rod Bearing................207
Clean and Inspect Pistons................208
Piston Ring Groove................209
Install Piston Rings................210
Piston Rings Staggering................211
Piston/Liner Set Information................212
Assemble Piston and Connecting Rod................213
Install Piston and Connecting Rod................214
Measure Piston Protrusion................215
Group 20: Crankshaft, Main Bearings and Flywheel................108
Summary of References—Crankshaft, Main Bearings and Flywheel................218
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Remove Crankshaft Pulley................223
Install Crankshaft Pulley................224
Remove Flywheel................226
Remove, Inspect and Install Flywheel Housing................227
Flywheel Ring Gear Replacement................229
Install Flywheel................230
Remove Crankshaft Rear Main Bearing Carrier................231
Inspect Crankshaft Rear Main Bearing Carrier................232
Install Crankshaft Rear Main Bearing Carrier................233
Remove Center Main Bearing Carrier................234
Inspect Center Main Bearing Carrier................235
Install Center Main Bearing Carrier................236
Check Piston Cooling Jets................237
Crankshaft End Play Measure................238
Remove Crankshaft................240
Inspect Crankshaft................241
Check Crankshaft Journal Diameter................242
Determine Crankshaft Main Bearing Clearance................243
Regrind Crankshaft................244
Crankshaft Regrinding Guidelines................245
Micro-Finishing Specifications................851
Replace Crankshaft Gear................247
Install Main Bearing Inserts................248
Install Crankshaft................249
Group 25: Camshaft and Timing Gear Train................109
Summary of References—Camshaft and Timing Gear Train................251
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Remove, Inspect and Install Timing Gear Cover................256
Remove, Inspect and Install Timing Gears................258
Measure Timing Gear Backlash................260
Remove Camshaft................261
Remove and Install Gear Support................262
Measure Camshaft Journal................263
Measure Height of Cam Lobe................264
Replace Camshaft Gear................265
Install Camshaft................266
Install Auxiliary Equipment................268
Group 30: Lubrication System................109
Summary of References—Lubrication System................270
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Remove Oil Cooler................274
Install Oil Cooler................275
Remove Oil Pressure Regulating Valve................276
Install Oil Pressure Regulating Valve................277
Replace Oil Dipstick Guide................278
Replace Oil Pump Strainer................279
Remove Oil Pump................280
Oil Pump Gear Axial Clearance................281
Oil Pump Gear Radial Clearance................282
Oil Pump Specifications................851
Oil Pump Installation................284
Remove and Install Oil Pan................285
Group 35: Cooling System................110
Summary of References—Cooling System................288
Special or Essential Tools................1379
Specifications................851
Torques for Hardware................291
Remove and Inspect Radiator................292
Water Pump — Exploded View................295
Remove Water Pump................296
Install Water Pump................298
Inspect Thermostat................300
Remove and Install Fan Belt................302
Check Fan/Alternator Belt Tension................303
Remove and Install Fan................306
Install Radiator................308
Replace Thermostat................310
Section 30: Fuel and Air Repair................313
Group 05: Fuel System................313
Summary of References—Fuel System................315
Special or Essential Tools................1379
Remove, Inspect and Install Fuel Tank................740
Remove, Inspect and Install Fuel Transfer Pump................320
Replace Fuel Filter................322
Replace Fuel Filter Assembly................323
Remove Fuel Injection Pump................324
Repairs to Fuel Injection Pump................327
Replace Throttle Lever................328
Install Fuel Injection Pump................329
Remove and Install Fuel Injection Nozzle................331
Clean Fuel Injection Nozzle................333
Fuel Injection Nozzle Disassembly................334
Group 10: Air Intake and Exhaust System................313
Summary of References—Air Intake and Exhaust System................336
Remove, Inspect and Install Air Cleaner Elements................337
Exhaust Manifold Inspection................339
Remove Turbocharger................340
Repair Turbocharger................341
Install Turbocharger................342
Turbocharger Break-In................344
Recommendations for Turbocharger Use................345
Group 15: Speed Control Linkage................313
Inspect and Repair Speed Control Linkage................349
Section 40: Electrical Repair................352
Group 05: Battery, Starter and Alternator................352
Summary of References—Battery, Starter and Alternator................354
Remove and Install Battery................355
Remove and Install Starter................357
Replace Alternator/Regulator................359
Group 10: Electrical System Components................352
Summary of References—Electrical System Components................361
Service Equipment and Tools................603
Other Material................671
Replace Air Filter Restriction Sensor................364
Replace Coolant Temperature Sender................365
Replace Engine Oil Pressure Sensor................366
Replace Key Switch................367
Replace Light Switch................368
Replace Turn Signal Controller................369
Replace Instrument Panel................370
Replace Rear PTO Switch................371
Replace Park Position Switch................372
Replace Fuel Level Sender................373
Group 15: Wiring Harness................352
Special or Essential Tools................1379
Service Parts Kits................621
Remove Connector Body from Blade Terminals................377
Section 50: Power Train Repair................378
Group 05: Clutch Housing................378
Summary of References—Clutch Housing................382
Service Equipment and Tools................603
Other Material................671
Specifications................851
Separate Engine from Clutch Housing................386
Install Engine to Clutch Housing................390
Inspect and Repair Clutch Pedal and Linkage................395
Group 10: Clutch Assembly................378
Summary of References—Clutch Assemble................398
Essential Tools................852
Service Equipment and Tools................603
Other Material................671
Specifications................851
Remove and Install Clutch Assembly................403
Disassemble and Inspect Clutch Assembly................405
Assemble Clutch Assembly................412
Traction Clutch Finger Adjustment................418
PTO Clutch Finger Adjustment................419
Remove and Inspect Clutch Release Mechanism................420
Install Clutch Release Mechanism and Shafts................424
Group 15: Transmission................378
Summary of References—Transmission................428
Specifications................851
Separate Clutch Housing From Transmission................430
Install Clutch Housing to Transmission................434
Inspect and Repair Gear Shift Lever................439
Inspect and Repair Range Shift Lever................444
Inspect and Repair Mode Selection Lever................446
Inspect and Repair 20% Reduction and Reverse Selection Lever................448
Remove Transmission................450
Disassemble and Inspect Transmission................455
Assemble Transmission................471
Install Transmission................487
Remove, Inspect and Install Cone Type Synchronizer................495
Group 20: Rear PTO Drive Shaft................379
Summary of References—Rear PTO Drive Shaft................497
Other Material................671
Specifications................851
Remove, Inspect and Install Rear PTO Lever and Linkage................500
Remove and Install Standard Rear PTO Drive Shaft Assembly................502
Disassemble, Inspect and Assemble Standard Rear PTO Drive Shaft Assembly................503
Group 25: Differential................379
Summary of References—Differential................506
Essential Tools................852
Service Equipment and Tools................603
Other Material................671
Specifications................851
Service Parts Kits................621
Remove and Install Differential Assembly................512
Disassemble, Inspect, and Assemble Differential Assembly................514
Remove and Inspect Differential Drive Shaft................516
Install Differential Drive Shaft................518
Remove, Inspect and Install Differential Lock Assembly................521
Differential Lock Mechanism................522
Differential Cone Point Adjustment................524
Differential Backlash Adjustment................525
Group 30: Final Drives................379
Summary of References—Final Drives................529
Service Equipment and Tools................603
Other Material................671
Specifications................851
Remove and Install Final Drive Assembly................533
Remove and Inspect Inboard Planetary Drive Assembly................535
Install Inboard Planetary Drive Assembly................537
Remove, Inspect and Install Axle Shaft Assembly................539
Group 35: Mechanical Front Wheel Drive................380
Summary of References—Mechanical Front Wheel Drive................542
Essential Tools................852
Other Material................671
Specifications................851
Inspect and Repair MFWD Lever and Linkage................546
Remove and Install MFWD Drop Gearbox................548
Disassemble and Inspect MFWD Drop Gearbox................550
Assemble MFWD Drop Gearbox................552
Remove, Inspect and Install MFWD Drive Shaft................557
Remove and Install MFWD Axle Housing Assembly................559
Remove, Inspect and Install MFWD Axle Supports................561
Disassemble and Inspect MFWD Outer Drive................563
Assemble MFWD Outer Drive................565
Remove, Inspect, and Install MFWD Swivel Housing................568
Remove, Inspect, and Install MFWD Axle Shaft................572
Remove and Install MFWD Differential Carrier Assembly................575
Disassemble and Inspect MFWD Differential Carrier Assembly................577
Assemble MFWD Differential Carrier Assembly................582
Section 60: Steering and Brake Repair................587
Group 05: Steering Repair................587
Summary of References—Steering Repair................589
Other Material................671
Specifications................851
Service Parts Kits................621
Remove and Install Steering Column and Valve................593
Remove and Install Steering Cylinder................595
Disassemble, Inspect and Assemble Steering Cylinder................597
Remove, Inspect and Install Tie Rod Assembly................599
Group 10: Brake Repair................587
Summary of References—Brake Repair................602
Service Equipment and Tools................603
Other Material................671
Specifications................851
Remove and Install Brake Pedals................606
Disassemble and Inspect Brake Pedals................608
Assemble of Brake Pedals................609
Remove and Inspect Brakes................610
Remove, Inspect and Install Brake Plate Assembly................612
Install Brakes................614
Section 70: Hydraulic Repair................616
Group 05: Hydraulic Pump and Filter................616
Summary of References—Hydraulic Pump and Filter................619
Specifications................851
Service Parts Kits................621
Remove and Install Hydraulic Pump................622
Remove Hydraulic Pump External Components................624
Install Hydraulic Pump External Components................625
Remove and Install Hydraulic Oil Filter/Manifold................626
Inspect and Replace Hydraulic Supply and Suction/Return Lines................628
Group 10: Rockshaft (85F, 100F)................616
Summary of References—Rockshaft (85F, 100F)................632
Other Material................671
Specifications................851
Remove, Inspect and Install Rockshaft Control Lever Assembly................635
Remove, Inspect and Install Rockshaft Control Lever Support Assembly................636
Remove, Inspect and Install Rockshaft Control Linkage................677
Remove, Inspect and Install Rate-of-Drop Valve................689
Replace Rockshaft Control Valve................691
Remove and Install Rockshaft Case................695
Remove, Inspect and Install Rockshaft Lift Arms................698
Remove, Inspect and Install Rockshaft Piston and Cylinder................702
Group 15: Rockshaft (76F)................616
Summary of References—Rockshaft (76F)................670
Other Material................671
Specifications................851
Remove, Inspect and Install Rockshaft Control Lever and Support Assembly................673
Remove, Inspect and Install Rockshaft Control Linkage................677
Remove, Inspect and Install Rate-of-Drop Valve................689
Replace Rockshaft Control Valve................691
Remove and Install Rockshaft Case................695
Remove, Inspect and Install Rockshaft Lift Arms................698
Remove, Inspect and Install Rockshaft Piston and Cylinder................702
Group 20: Selective Control Valve (SCV)................617
Summary of References—Selective Control Valve (SCV)................704
Remove and Install Selective Control Valves (85F, 100F)................705
Remove and Install Selective Control Valves (76F)................707
Remove and Install Rear Quick Coupler - 76F................709
Section 80: Miscellaneous Repair................711
Group 10: Wheels................711
Summary of References—Wheels................713
Specifications................851
Tighten Bolts—Front Axle................715
Tighten Bolts—Rear Axle................716
Group 15: 3-Point Hitch................711
Summary of References—3-Point Hitch................718
Inspect and Repair Draft Links................719
Inspect and Repair Center Link................722
Inspect and Repair Lift Link for 76F Tractors................724
Inspect and Repair Lift Link for 85F and 100F Tractors................727
Section 90: Operator Station Repair................729
Group 05: Seat and Support................729
Remove and Install Seat and Support................732
Group 10: Roll-GardROLL-GARD is a trademark of Deere & Company.................729
Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.................729
Group 15: Operator Platform................729
Summary of References—Operator Platform................738
Specifications................851
Remove, Inspect and Install Fuel Tank................740
Remove and Install Open Operator Station................741
Remove, Inspect and Install Cab................750
Group 20: Fenders................729
Summary of References—Fenders................756
Remove and Install Mudguard................757
Remove and Install Fenders................759
Group 25: Air Conditioning System................729
Summary of References—Air Conditioning System................761
Essential Tools................852
Specifications................851
Torques for Tightening Refrigerant Hoses................767
Safety At Work................768
Handling Refrigerant................769
In An Emergency................770
Safety Equipment................1374
Storage of Refrigerant Containers................1376
R134a Refrigerant................1377
Important................774
Discharging the System................775
Evacuating the System................777
Filling With Refrigerant Oil................779
Filling the System................781
Topping Up a Partly Discharged System................784
Leakage Test................786
Replace Air Conditioning Receiver-Drier................1370
Remove, Inspect, and Install Air Conditioning Condenser................1369
Remove, Inspect and Install Air Conditioning Compressor................1368
Check Level in the Compressor................1368
Air Conditioning Evaporator—Parts................793
Remove and Install Air Conditioning Evaporator................794
Remove and Install Cab Air Filters................797
Group 35: Operator’s Cab................730
Summary of References—Operator's Cab................799
Specifications................851
Remove and Install Front Windshield................801
Remove and Install Front Windows................802
Remove and Install Cab Door................803
Remove and Install Rear Side Cab Windows................805
Remove and Install Rear Window................806
Section 210: Operational Checkout Procedures................807
Group 10: Operational Checkout Procedures................807
Summary of References—Operational Checkout Procedures................809
Operational Checkout Procedure Information................810
Engine Oil Level and Condition Check................811
Coolant Level and Condition Check................812
Transmission and Hydraulic Oil Check................813
Fan and Belt Check................814
Fuel System Check................815
Air Intake System Check................816
Electrical System Check................818
Hydraulic System Check................819
Indicator Lamps Check................820
Engine Start Check................821
Transmission Park Position Start Check................822
Engine Fast and Slow Idle Operation................823
Power Steering Check................824
Differential Lock Check................825
Clutch Check................826
Transmission Shift Check................827
Range Lever Shift Check................828
Brake Check................829
Rockshaft Check................830
Selective Control Valve Check................832
Miscellaneous Checks................834
Section 220: Engine Operation, Tests and Adjustments................835
Group 05: Component Location................835
Summary of References—Component Location................1278
Component Location Information................1279
Engine External Components—Right-Hand Side................840
Engine External Components—Left-Hand Side................841
Group 10: Theory of Operation................835
Summary of References—Theory of Operation................1360
Theory of Operation Information................1361
Engine Lubrication System................845
Engine Cooling System Operation................847
Group 15: Diagnosis, Tests and Adjustments................835
Summary of References—Diagnosis, Tests and Adjustments................1262
Specifications................851
Essential Tools................852
Diagnostic Information................1382
Engine Turns Over But Will Not Start or Starts Hard................854
Engine Runs Irregularly or Stalls Frequently................855
Engine Runs Rough................856
Engine Has Low Power................857
Engine Smokes—Black or Grey................858
Engine Smokes Excessively—White................859
Engine Uses Excess Fuel................860
Engine Has Excess Noise or Vibration................861
Engine Uses Excess Oil or Smokes Blue................862
Engine Has Low Oil Pressure................863
Engine Coolant Operating Temperature Incorrect................864
Oil In Coolant or Coolant in Oil................866
Cooling System Test................867
Radiator Cap Pressure Test................868
Engine Oil Pressure Test................869
Cylinder Compression Pressure Test................871
Fuel Shut-Off Solenoid Check................873
Idle Speed Adjustment................874
Adjust Throttle Friction................876
Injection Pump Timing Adjustment................877
Top Dead Center Adjustment................881
Fan/Alternator Drive Belt Adjustment................884
Bleed Fuel System................886
Section 230: Fuel/Air Operation, Test and Adjustments................888
Group 05: Component Location................888
Summary of References—Component Location................1278
Component Location Information................1279
Fuel System Components................892
Air Intake System Components................893
Group 10: Theory of Operation................888
Summary of References—Theory of Operation................1360
Theory of Operation Information................1361
Fuel System Operation................897
Fuel Injection Pump Operation................899
Air Intake System Operation................901
Turbocharger Operation................903
Check Turbocharger Boost Pressure................904
Check Exhaust Back Pressure................905
Diagnosing Turbocharger Malfunctions................906
Group 15: Diagnosis, Tests and Adjustments................888
Summary of References—Diagnosis, Tests and Adjustments................1262
Diagnostic Information................1382
Fuel/Air Diagnosis, Tests and Adjustments................910
Section 240: Electrical System Operation, Tests and Adjust................911
Group 00: Operation and Tests—General................911
Operation and Tests—General (Summery of References)................918
Theory of Operation Information................1361
Diagnostic Information................1382
Theory of Operation—Fuse Block and Fuses................921
Theory of Operation—Relays................922
JT05791A - Multimeter................923
Fuse Test................924
Relay Test................925
Group 15: Diagnosis, Tests, and Adjustments—Electrical................911
Battery Dead, Tachometer, and Air Conditioning Not Working................927
Group S01: SE01—Starting System................911
SE01—Starting System (Summery of References)................929
Diagnostic Schematic, SE01—Starting System Functional Schematic and Circuit Diagram................930
Diagnostic Schematic, SE01—Air Pre Heater Functional Schematic and Circuit Diagram................931
Voltage Checks................932
Starter AMP Draw/RPM Test................939
Starter No-Load AMP Draw/RPM Test................941
Group S02: SE02—Charging System................911
SE02—Charging System (Summery of Reference)................944
Diagnostic Schematic, SE02—Charging System Functional Schematic and Circuit Diagram................945
Alternator/Regulator Test................947
Battery Voltage and Specific Gravity Tests................949
Charge Battery................951
Battery Load Test................953
Group S03: SE03—Instrument Panel................911
SE03—Instrument Panel (Summery of Reference)................956
Diagnostic Schematic, SE03—Instrument Panel Functional Schematic and Circuit Diagram................957
B01—Hydraulic Oil Temperature Sensor (Restriction Sensor) Circuit/Harness Test................959
B02—Air Filter Restriction Sensor Circuit/Harness Test................961
B03—Coolant Temperature Sensor Circuit/Harness Test................963
B04—Engine Oil Pressure Sensor Circuit/Harness Test................965
B05—Transmission Speed Sensor Circuit/Harness Test................967
B06—Engine Speed Sensor Circuit/Harness Test................970
B08—Fuel Level Sensor Circuit/Harness Test................973
B09—Transmission Speed Selection Switch Circuit/Harness Test................975
Group S04: SE04—Lighting System................912
SE04—Lighting System (Summery of Reference)................978
Diagnostic Schematic, SE04—Lighting System Functional Schematic and Circuit Diagram................979
E01, E02—Head Lights Circuit/Harness Test................981
E05—Tail Light (Right-Hand Side) Circuit/Harness Test................984
E08—Tail Light (Left-Hand Side) Circuit/Harness Test................986
E09—Rear Work Light (Right-Hand Side) Circuit/Harness Test................988
E10—Rear Work Light (Left-Hand Side) Circuit/Harness Test................990
Group S05: SE05—Turn Signal and Hazard Warning Lights................912
SE05—Turn Signal and Hazard Warning Lights (Summery of Reference)................993
Diagnostic Schematic, SE05—Turn Signal Lights Functional Schematic and Circuit Diagram................994
Diagnostic Schematic, SE05—Hazard Warning Lights Functional Schematic and Circuit Diagram................996
E03—Rear Right-Hand Side Turn Signal Light Circuit/Harness Test................998
E04—Front Right-Hand Side Turn Signal Light Circuit/Harness Test................1000
E06—Front Left-Hand Side Turn Signal Light Circuit/Harness Test................1002
E07—Rear Left-Hand Side Turn Signal Light Circuit/Harness Test................1004
Hazard Warning Lights Circuit/Harness Test................1006
Group S06: SE06—Horn................912
SE06—Horn (Summery of References)................1008
Diagnostic Schematic, SE06—Horn Functional Schematic and Circuit Diagram................1009
H01—Horn Circuit/Harness Test................1010
Group S08: SE08—Parking Brake................912
SE08—Parking Brake (Summery of References)................1013
Diagnostic Schematic, SE08—Parking Brake Functional Schematic and Circuit Diagram................1014
B13—Parking Brake Circuit/Harness Test................1016
Group S10: SE10—Rear PTO Warning System................912
SE10—Rear PTO Warning System (Summery of References)................1020
Diagnostic Schematic, SE10—Rear PTO Warning System Functional Schematic and Circuit Diagram................1021
H02—PTO Buzzer Circuit/Harness Test................1023
Group S11: SE11—Front Wheel Drive................913
SE11—Front Wheel Drive (Summery of References)................1027
Diagnostic Schematic, SE11—Front Wheel Drive Functional Schematic and Circuit Diagram................1028
B14—Front Wheel Drive Switch Circuit/Harness Test................1030
Group S12: SE12—7-Pin Connector for Trailer Lights................913
SE12—7-Pin Connector for Trailer Lights (Summery of References)................1034
Diagnostic Schematic, SE12—7-Pin Connector for Trailer Lights Functional Schematic and Circuit Diagram................1035
X07—7-Pin Connector for Trailer Lights Circuit/Harness Test................1037
Group 105: Component Information—Connectors................913
Component Information—Connectors (Summery of References)................1042
X01—34-Pin Interconnection Between Wiring Harness W01/1 and W01/2................1043
X03—4-Pin Connector for E01 and E02 Head Lights................1046
X04—14-Pin Connector for Power Supply to Safety Switches................1048
X05—4-Pin Connector for Right-Hand Side Turn Signal Lights E03, E04, and Tail Light E05................1049
X06—4-Pin Connector for Left-Hand Side Turn Signal Lights E06, E07, and Tail Light E08................1050
X07—7-Pin Connector for Trailer Lights................1051
X08—18-Pin Connector for Dashboard................1052
X09—12-Pin Connector for Dashboard................1054
X10—24/1-Pin Connectors for Fuses F01 to F12................1056
XB01—1-Pin Connector for Hydraulic Oil Temperature Sensor B01 (Restriction Sensor)................1057
XB02—2/1-Pin Connectors for Air Filter Restriction Sensor B02................1058
XB08—3-Pin Connector for Fuel Level Sensor B08................1059
XB11—2-Pin Connector for Seat Switch B11................1060
XB12—4-Pin Connector for PTO Safety Switch B12................1061
XB13—3-Pin Connector for Parking Brake Switch B13................1062
XB15—2-Pin Connector for Neutral Start Switch B15................1063
XG01—2/1-Pin Connectors for Battery G01................1064
XH01—1-Pin Connector for Horn H01................1065
XH02—3/1-Pin Connector for PTO Buzzer H02................1066
XK01—4-Pin Connector for Starting Relay K01................1067
XK02—5-Pin Connector for Advance Start Relay K02................1068
XK07—7-Pin Connector for Air Pre Heater Relay K07................1069
XK08—24-Pin Connector for Flasher Unit K08................1071
XS01—5/1-Pin Connectors for Main Switch S01................1072
XS02—6/1-Pin Connectors for Light Switch S02................1073
XS03—5/1-Pin Connectors for Turn Signal Switch S03................1074
XS04—8-Pin Connector for Hazard Warning Light Switch S04................1075
Group 110: Component Information—Wiring Harnesses................1077
Component Information—Wiring Harnesses................1077
W01/1—Main Wiring Harness................1078
W01/2—Main Wiring Harness................1081
Group 115: Component Information—Electrical Parts................1085
Component Information—Electrical Parts................1085
B01—Hydraulic Oil Temperature Sensor (Restriction Sensor)................1087
B02—Air Filter Restriction Sensor................1089
B03—Coolant Temperature Sensor................1091
B04—Engine Oil Pressure Sensor................1093
B05—Transmission Speed Sensor................1095
B06—Engine Speed Sensor................1096
B08—Fuel Level Sensor................1098
B09—Transmission Speed Selection Switch................1100
B10—PTO Switch................1102
B11—Seat Switch................1104
B12—PTO Safety Switch................1106
B13—Parking Brake Switch................1108
B14—Front Wheel Drive Switch................1110
B15—Neutral Start Switch................1112
E01—Headlight Left-Hand Side................1114
E02—Headlight Right-Hand Side................1115
E03—Rear Right-Hand Side Turn Signal Light................1116
E04—Front Right-Hand Side Turn Signal Light................1117
E05—Tail Light (Right-Hand Side)................1118
E06—Rear Left-Hand Side Turn Signal Light................1119
E07—Front Left-Hand Side Turn Signal Light................1120
E08—Tail Light (Left-Hand Side)................1121
E09—Work Light (Right-Hand Side)................1122
F00—Fuse (+70 A)................915
F01 to F12—Fuse Box................1124
G01—Battery................1125
G02—Alternator................1126
H01—Horn................1127
H02—PTO Buzzer................1128
K01—Starting Relay................1129
K02—Advance Start Relay................1130
K03—Raise Seat Timer Relay................1131
K04—PTO Timer Relay................1132
K05—PTO Alarm Relay................1133
K06—PTO Relay................1134
K07—Air Pre Heater Relay................1135
K08—Flasher Unit................1136
M01—Starter Motor................1137
R01—Air Pre Heater................1138
S01—Main Switch................1139
S02—Light and Horn Switch................1140
S03—Turn Signal Switch................1142
S04—Hazard Warning Light Switch................1144
Y01—Fuel Shut-off Solenoid Valve................1146
Y02—Fuel Shut-off Solenoid Valve (On Fuel Filter)................1148
Y03—Advance Variation Solenoid Valve................1150
Group 120: Component Information—Ground Connections................915
Component Information—Ground Connections (Summery of References)................1153
XGND01—Ground Connection for Wiring Harness W01/1................1154
XGND02—Ground Connection for Wiring Harness W01/2................1155
Group 200: Wiring Diagrams................915
Wiring Diagrams (Summery of References)................1157
Schematic Information................1158
Component Identification Table................1159
Wire Color Codes................1161
Wiring Schematic, W01—Main Wiring Harness I................1162
Wiring Schematic, W01—Main Wiring Harness II................1164
Section 250: Power Train Operation, Tests and Adjustments................1166
Group 05: Component Location—Transmission................1166
Summary of References—Component Location—Transmission................1169
Component Location Information................1279
Power Train Components................1171
Clutch Components................1172
Transmission Components................1174
Final Drive Components................1176
Rear PTO Components................1177
Group 10: Theory of Operation—Transmission................1166
Summary of References—Theory of Operation—Transmission................1179
Theory of Operation Information................1361
Clutch Operation—Dual Clutch................1181
Gear Shift Power Flow (8+8)................1166
Range Shift Power Flow (8+8)................1166
Power Reverse Flow (8+8)................1166
Gear Shift Power Flow (16+8)................1166
Range Shift Power Flow (16+8)................1166
20% Reduction Power Flow (16+8)................1166
Mechanical Front Wheel Drive (MFWD) Operation................1199
Rear PTO Operation................1201
Differential Power Flow................1203
Differential Lock Operation................1205
Final Drive Operation................1207
Group 15: Diagnosis, Tests, and Adjustments—Transmission................1166
Summary of References—Diagnosis, Tests, and Adjustments-Transmission................1210
Diagnostic Information................1382
Isolate the Problem Area................1213
Traction Clutch Slips................1215
Traction Clutch Dragging................1216
Traction Clutch Does Not Engage................1217
Traction Clutch Grabs................1218
Traction Clutch Squeaks................1219
Traction Clutch Does Not Release................1220
Traction Clutch Chatters................1221
Traction Clutch Rattles................1222
Traction Clutch Engagement is Noisy................1223
Excessive Vibration in Traction Clutch................1224
Clutch Pedal Does Not Return................1225
Clutch Pedal Loose................1226
Clutch Pedal Pulsates................1227
Jerky or Rough Transmission of Power................1228
Low Transmission Oil Level (Excessive Oil Leakage)................1229
Gears Clash, Shift Hard, or Will Not Engage................1230
Two Speeds Engage Together................1231
Transmission Will Not Stay in Gear................1232
Transmission Noisy................1233
PTO Noisy................1234
PTO Hard to Engage................1235
PTO Will Not Operate................1236
PTO Will Not Stay Engaged................1237
Excessive Differential Noise................1238
Differential Does Not Work................1239
No Differential Lock................1240
Differential Chatters................1241
Axle Noise................1242
Axle Shaft Will Not Turn................1243
Check and Adjust Clutch Pedal Free Play................1244
Adjusting PTO Clutch Lever Linkage................1245
Section 260: Steering and Brake Operation, Test Section 260: Steering and Brake Operation, Test & Adjustments{pgNO}1246 Adjustments................1246
Group 05: Component Location................1246
Summary of References—Component Location................1278
Component Location Information................1279
Steering System Components................1250
Group 10: Theory of Operation................1246
Summary of References—Theory of Operation................1360
Theory of Operation Information................1361
Steering System Operation................1255
Steering Valve Operation—Park Position and Manual Turning................1257
Steering Valve Operation—Power Turning................1259
Group 15: Diagnosis, Tests and Adjustments................1246
Summary of References—Diagnosis, Tests and Adjustments................1262
Diagnostic Information................1382
Isolate the Problem—Steering System................1264
Steering Sluggish or Loss of Steering................1265
Isolate the Problem—Brakes................1266
Excessive Brake Pedal Leak-Down................1267
Excessive Brake Chatter................1268
Steering valve Relief Test................1269
Steering Cylinder Leakage Test................1270
Checking Toe-In................1271
Adjusting Toe-In................1272
Brake Pedal Adjustment................1273
Section 270: Hydraulic System Operation, Test and Adjustments................1275
Group 05: Component Location................1275
Summary of References—Component Location................1278
Component Location Information................1279
Hydraulic System Components................1280
Group 10: Theory of Operation................1275
Summary of References—Theory of Operation................1360
Theory of Operation Information................1361
Hydraulic System Operation................1285
Hydraulic Pump Operation................1288
MITA Selective Control Valve—Neutral Position................1290
MITA Selective Control Valve—Retract Position................1292
MITA Selective Control Valve—Extend Position................1294
MITA Selective Control Valve—Float Position................1296
Rockshaft Control Valve Operation—Neutral Position................1298
Rockshaft Control Valve Operation—Raise Position................1300
Rockshaft Control Valve Operation—Lower Position................1302
Surge Relief Valve Operation................1304
Rate-of-Drop Valve Operation—Full Open................1306
Rate-of-Drop Valve Operation—Partially Open................1308
Rate-of-Drop Valve Operation—Full Closed................1310
Rockshaft Draft - Sensing Operation................1312
Functioning of Position Control (76F)................1314
Functioning of Draft Control (76F)................1316
Combined Functioning of Position and Draft Control................1318
Group 15: Diagnosis................1275
Summary of References—Diagnosis................1320
Diagnostic Information................1382
Preliminary Hydraulic System Inspection................1322
Entire Hydraulic System Fails to Function/No Hydraulic Pump Output................1323
Insufficient Pump Delivery................1324
Hydraulic Functions Too Slow................1325
Excessive Pump Pressure................1326
Slow Hydraulic Pump Response................1327
Excessive Pump Noise During Operation................1328
Rockshaft Does Not Lift or Lifts Slowly................1329
Rockshaft Does Not Lower or Lowers Slowly................1330
Park Position Unstable, Rockshaft Drops after Engine Shut Down................1331
Group 17: Hydraulic Tests................1276
Summary of References—Hydraulic Tests................1333
Hydraulic System Tests................1334
Pump Flow Test................1335
Main Relief Valve Test................1337
Rockshaft Leakage Test................1338
Rockshaft Lift Cycle Test................1339
Group 20: Adjustments................1276
Summary of References—Adjustments................1341
Rockshaft Sensing Lever Friction Adjustment................1342
Control of Assembly of Reaction Spring................1343
Measurement Control of Push Rod................1345
Adjustment of Position Control Lever— 76F Tractors................1346
Adjustment Of Draft Control Lever — 76F Tractors................1347
Adjustment of Position Control Lever— 85F and 100F Tractors................1348
Adjustment Of Draft Control Lever — 85F and 100F Tractors................1349
Group 45: Hydraulic Schematics................1276
Hydraulic Circuit Symbols................1352
Section 290: Air Conditioning System—Operation and Tests................1354
Group 05: Component Location................1354
Component Location (Summery of References)................1356
General Information................1357
Air Conditioning System Components................1358
Group 10: Theory of Operation................1354
Summary of References—Theory of Operation................1360
Theory of Operation Information................1361
Principle of Heat Exchange................1362
R134a Refrigerant................1377
Operation of Air Conditioning System—Air Flow................1364
Air-Conditioning System Operation................1366
Compressor................1368
Condenser................1369
Receiver-Drier................1370
Expansion Valve................1371
Group 15: Diagnosis, Tests and Adjustments................1354
Diagnosis, Tests and Adjustments (Summary of Reference)................1373
Safety Equipment................1374
In an Emergency................1375
Storage of Refrigerant Containers................1376
R134a Refrigerant................1377
Important Note................1378
Special or Essential Tools................1379
Special Tools................1380
Diagnostic Information................1382
Air Conditioning System Diagnosis................1383
Pressure Deviations................1392
Air Conditioning System Trouble-Shooting................1394
Failure Of Mechanical Type................1398
Section 299: Special Tools................1400
Group 10: Special Tools (Available as Spare Parts)................1400
Summary of References—Special Tools (Available as Spare Parts)................1402
JDG68400025A — Extractor Injection Pump................1403
JDG68400037F — Extractor Injection Pump................1404
JDG68420012A — Socket................1405
JDG68420017F — Socket................1406
JDG68490014F — Dial Gauge Injection Pump Timing................1407
JDG68490020F — Shaft TDC................1408
JDG68400004A — Extractor Injector................1409
JDG68420016F — Head Bolt Socket................1410
JDG68420015F — Head Bolt Socket................1411
John Deere Tractors 76F, 85F, 100F Diagnostic & Repair Servicve Technical Manual (TM103319)
