Complete Diagnosis Operation Test Repair Service Manual with electrical wiring diagrams for John Deere Compact Utility Tractors 1023E & 1026R (Worldwide), with workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere 1023E & 1026R Worldwide Compact Utility Tractors workshop diagnostic & repair 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.

tm109719 - 1023E and 1026R Compact Utility Tractor Technical Manual.pdf
tm109719 - 1023E and 1026R Compact Utility Tractor Technical Manual.epub

Total Pages: 1,056 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features and Accessories
   Engine Repair
      Engine
      Cooling System
   Fuel and Air Repair
      Fuel System
      Air Intake and Exhaust Systems
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Transmission
      Rear PTO Driveshaft
      Differential
      Final Drives
      Mechanical Front Wheel Drive
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulics Repair
      Hydraulic Pump and Filter
      Rockshaft
      Selective Control Valve
   Miscellaneous Repair
      Wheels
      3-Point Hitch
      Hood
      Mid-Mount Lift
   Operator`s Station Repair
      Seat and Support
      ROLL-GARD
      Operator Platform
      Fenders
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests, and Adjustments
   Fuel and Air Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjustments
   Electrical System Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjustments
      Wiring Schematics
      Connector Information
   Power Train Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjustments
   Steering and Brake Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjustments
   Hydraulic System Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests
      Adjustments
      Hydraulic Schematics
   Service Tools
      Dealer Fabricated Tools
      Service Tools and Kits

tm109719 - 1023E and 1026R Compact Utility Tractor

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Handle Fuel Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service and Operate Chemical Sprayers Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Prevent Machine Runaway

Handle Starting Fluid Safely

Service Cooling System Safely

Stay Clear of Rotating Drivelines

Protect Against High Pressure Spray

Construct Dealer-Made Tools Safely

Clean Vehicle of Hazardous Pesticides

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Live With Safety

Group 10: General Specifications

Machine Specifications 1023E, and 1026R

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values—Grade 7

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Do Not Use Galvanized Containers

Lubricity of Diesel Fuel

Testing Diesel Fuel

Biodiesel Fuel

Filling Fuel Tank

Diesel Engine Break-In Oil

Diesel Engine Oil

Oil Filters

Heavy Duty Diesel Engine Coolant

Operating in Warm Temperature Climates

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

Testing Diesel Engine Coolant

Transmission and Hydraulic Oil

Use Correct Transmission/Hydraulic Filter Element

MFWD Axle Housing and Wheel Hub Oil

Grease

Grease (Specific Application)

Mixing of Lubricants

Alternative and Synthetic Lubricants

Lubricant Storage

Group 20: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Group 25: Features and Accessories

Features and Accessories

Section 20: Engine Repair

Group 05: Engine

Summary of References

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Remove Engine

Install Engine

Remove and Install Valve Cover

Remove and Install Rocker Arm Assembly and Push Rods

Disassemble, Inspect, and Assemble Rocker Arm Assembly and Push Rods

Remove and Install Exhaust Manifold

Remove and Install Cylinder Head

Disassemble and Assemble Cylinder Head

Recondition Cylinder Head

Replace Crankshaft Rear Oil Seal: 3TNM72

Replace Crankshaft Rear Oil Seal: 3TNV76

Remove and Install Crankshaft Rear Oil Seal Case: 3TNV76

Replace Crankshaft Front Oil Seal

Remove and Install Timing Gear Cover

Remove, Inspect, and Install Idler Gear

Remove, Inspect, and Install Camshaft Followers

Remove and Install Camshaft

Inspect Camshaft, Gear, Bushing and Bores

Remove and Install Oil Pan and Strainer: 3TNM72

Remove and Install Oil Pan and Strainer: 3TNV76

Check Connecting Rod Side Play

Check Crankshaft End Play

Check Connecting Rod Bearing Clearance

Check Crankshaft Main Bearing Clearance

Remove Piston and Connecting Rod

Install Piston and Connecting Rod

Disassemble and Inspect Piston and Connecting Rod

Assemble Piston and Connecting Rod

Inspect Cylinder Bore

Rebore Cylinder

Remove Crankshaft and Main Bearings: 3TNM72

Install Crankshaft and Main Bearings: 3TNM72

Remove Crankshaft and Main Bearings: 3TNV76

Install Crankshaft and Main Bearings: 3TNV76

Remove and Install Flywheel

Remove and Install Engine Back Plate

Inspect Oil Pump: 3TNM72

Inspect Oil Pump: 3TNV76

Group 10: Cooling System

Summary of References

Specifications

Remove and Install Fan and Alternator Belt

Remove and Install Radiator

Remove and Install Water Pump

Remove and Install Thermostat

Remove and Install Coolant Temperature Sensor

Install Block Heater: 3TNM72

Install Block Heater: 3TNV76

Section 30: Fuel and Air Repair

Group 05: Fuel System

Summary of References

Specifications

Other Material

Service Equipment and Tools

Bleed Fuel System

Remove and Install Fuel Transfer Pump

Remove and Install Fuel Injection Nozzle

Clean and Inspect Fuel Injection Nozzle

Remove Fuel Injection Pump: 3TNM72

Install Fuel Injection Pump: 3TNM72

Remove Fuel Injection Pump: 3TNV76

Install Fuel Injection Pump: 3TNV76

Remove and Install Fuel Shutoff Solenoid

Remove and Install Fuel Filter Assembly

Disassemble and Assemble Fuel Filter and Water Separator

Remove and Install Inline Fuel Filter

Group 10: Air Intake and Exhaust Systems

Summary of References

Remove and Install Muffler

Group 15: Speed Control Linkage

Summary of References

Replace Throttle Cable

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Summary of References

Specifications

Essential or Recommended Tools

Remove and Install Battery

Remove and Install Starting Motor

Remove and Install Alternator

Disassemble and Inspect Alternator

Assemble Alternator

Group 10: Electrical System Components

Summary of References

Electrical System Components (S.N. —209999)

Electrical System Components (S.N 210000— )

Electrical Components - EEC (S.N. —209999)

Electrical Components - EEC (S.N. 210000— )

Group 15: Wiring Harness

Summary of References

1023E Wiring Harness (S.N. —209999)

1023E Wiring Harness (S.N. 210000— )

1026R Wiring Harness (S.N. —209999)

1026R Wiring Harness (S.N. 210000— )

1026R EEC Wiring Harness (S.N. —209999)

1026R EEC Wiring Harness (S.N. 210000— )

Section 50: Power Train Repair

Group 15: Transmission

Summary of References

Specifications

Other Material

Remove Transmission

Install Transmission

Remove and Install Hydrostatic Drive

Disassemble and Inspect Hydrostatic Drive

Assemble Hydrostatic Drive

Remove and Install Range Transmission

Group 20: Rear PTO Driveshaft

Summary of References

Specifications

Other Material

Essential or Recommended Tools

Remove PTO Clutch

Disassemble and Inspect PTO Clutch

Assemble PTO Clutch

Install PTO Clutch

Remove and Inspect Rear PTO Driveshaft and Gears

Install Rear PTO Driveshaft and Gears

Remove and Inspect Mid PTO Driveshaft and Gears

Install Mid PTO Driveshaft and Gears

Group 25: Differential

Summary of References

Specifications

Other Material

Remove and Install Differential

Disassemble and Inspect Differential

Assemble Differential

Group 30: Final Drives

Summary of References

Essential or Recommended Tools

Remove and Install Rear Axle

Group 35: Mechanical Front Wheel Drive

Summary of References

Specifications

Remove Front Axle

Install Front Axle

Disassemble Front Axle

Assemble Front Axle

Disassemble Front Outer Axle

Assemble Front Outer Axle

Disassemble MFWD Differential

Assemble MFWD Differential

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Summary of References

Specifications

Remove and Install Steering Wheel

Remove and Install Steering Cylinder

Remove and Install Tilt Steering Assembly

Disassemble Tilt Steering Assembly

Assemble Tilt Steering Assembly

Remove Steering Control Unit (SCU)

Install Steering Control Unit (SCU)

Remove and Install Tie Rod

Group 10: Brake Repair

Summary of References

Specifications

Other Material

Disassemble and Inspect Brakes

Assemble Brakes

Section 70: Hydraulics Repair

Group 05: Hydraulic Pump and Filter

Summary of References

Specifications

Remove and Install Hydraulic Pump

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Remove and Install Oil Suction Screen

Remove PTO Valve

Install PTO Valve

Group 10: Rockshaft

Summary of References

Specifications

Other Material

Remove Rockshaft Housing

Install Rockshaft Housing

Disassemble Rockshaft

Assemble Rockshaft

1026R Disassemble Rockshaft Position Feedback

1026R Assemble Rockshaft Position Feedback

Group 15: Selective Control Valve

Summary of References

Specifications

Remove and Install Selective Control Valve (SCV)

Inspect Selective Control Valve (SCV)

Section 80: Miscellaneous Repair

Group 10: Wheels

Summary of References

Specifications

Remove and Install Front Wheels

Remove and Install Rear Wheels

Group 15: 3-Point Hitch

Summary of References

Adjust 3-Point Hitch

Remove and Install 3-Point Hitch

Group 20: Hood

Summary of References

Remove and Install Hood

Group 25: Mid-Mount Lift

Summary of References

Specifications

Remove Mid Mount Mower Draft Arm

Install Mid Mount Mower Draft Arm

Remove Mid Mount Rockshaft and Lift Arm

Install Mid Mount Rockshaft and Lift Arm

Install Mid Mount Lift Actuator, Mechanical

Install Mid Mount Lift Actuator, Hydraulic

Remove Mid Mount Mower Lift Hydraulic Hose and Cylinder

Install Mid Mount Mower Lift Hydraulic Cylinder and Hose

Adjust Mid Mount Lift - Mechanical Lift

Section 90: Operator's Station Repair

Group 05: Seat and Support

Summary of References

Specifications

Remove Seat

Install Seat

Remove Seat Base

Install Seat Base

Group 10: ROLL-GARD

Summary of References

Specifications

Remove ROPS

Install ROPS

Group 15: Operator Platform

Summary of References

Specifications

Remove Control Panel

Install Control Panel

Remove and Install Center Closeout Panel

Group 20: Fenders

Summary of References

Remove Right Fender

Install Right Fender

Remove Left Fender and Fuel Tank

Install Left Fender and Fuel Tank

Section 210: Operational Checkout Procedures

Group 05: Operational Checkout Procedures

Summary of References

System Checks

Rear Differential Lock Operational Check

PTO Operational Checks

RIO Operational Check

PTO and Seat Switch Interface Check

Brakes Operational Check

Steering Preliminary Check

Steering Operational Check

Hydraulic System Operational Checks

Section 220: Engine Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

3TNM72 Engine Component Locations

3TNV76 Engine Component Locations

Group 10: Theory of Operation

Summary of References

Cooling System Theory of Operation

Lubrication System Theory of Operation

Group 15: Diagnosis, Tests, and Adjustments

Summary of References

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Adjust Throttle Cable

Adjust Slow Idle

Adjust Fast Idle

Adjust Valve Clearance

Check Camshaft End Play

Check Timing Gear Backlash

Cylinder Compression Test—3TNV76

Cylinder Compression Test—3TNM72

Pressure Test Cooling System

Test Thermostat

Pressure Test Radiator Cap

Test Oil Pressure

Adjust Fan and Alternator Belt

Section 230: Fuel and Air Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Fuel System

Group 10: Theory of Operation

Summary of References

Air Intake System Theory of Operation

Fuel System Theory of Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Test Fuel Injection System

Test Fuel Injection Nozzle

Injection Pump Timing (EPA Engines)

Check Injection Pump Static Timing

Adjust Fuel Injection Timing: 3TNM72

Adjust Fuel Injection Timing: 3TNV76

Test Fuel Supply Pressure and Flow

Test Air Filter Restriction Indicator

Section 240: Electrical System Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Electrical Components (S.N. —209999)

Electrical Components (S.N. 210000— )

Electrical Components - EEC (S.N. —209999)

Electrical Components - EEC (S.N. 210000— )

Load Center - Domestic

Load Center - EEC

Group 10: Theory of Operation

Summary of References

Charging Circuit - 1023E

Cranking and Starting Circuit - 1023E

Instrument Control Cluster (ICC) - 1023E (S.N. —209999)

Instrument Control Cluster (ICC) - 1023E (S.N. 210000— )

Power Circuit - 1023E (S.N. —209999)

Power Circuit - 1023E (S.N. 210000— )

PTO Circuit - 1023E (S.N. —209999)

PTO Circuit - 1023E (S.N. 210000— )

Lighting Circuit - 1023E (S.N. —209999)

Lighting Circuit - 1023E (S.N. 210000— )

Charging Circuit - 1026R

Cranking and Starting Circuit - 1026R

Instrument Control Cluster (ICC) - 1026R (S.N. —209999)

Instrument Control Cluster (ICC) - 1026R (S.N. 210000— )

Power Circuit - 1026R (S.N. —209999)

Power Circuit - 1026R (S.N. 210000— )

PTO Circuit - 1026R (S.N. —209999)

PTO Circuit - 1026R (S.N. 210000— )

Lighting Circuit - 1026R (S.N. —209999)

Lighting Circuit - 1026R (S.N. 210000— )

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Essential or Recommended Tools

Power Circuit Diagnosis 1023E and 1026R

Charge Circuit Diagnosis 1023E and 1026R

Crank Circuit Diagnosis 1023E and 1026R

Fuel Shutoff Circuit Diagnosis 1023E and 1026R

Glow Plug Circuit Diagnosis 1023E and 1026R

PTO Circuit Diagnosis 1023E and 1026R

Lighting Circuit Diagnosis 1023E

Lighting Circuit Diagnosis 1026R

Instrument Control Cluster (ICC) Diagnosis

Key Switch Test

PTO Switch Test (S.N. —209999)

PTO Switch Test (S.N. 210000—)

Park Brake Switch Test

Reverse Pedal Switch Test (S.N. 210000— )

Reverse Pedal Switch Adjustment (S.N. 210000— )

Seat Switch Test

Light Switch Test

Turn Signal Switch Test

Hazard Switch Test

PTO MBR Switch Test

PTO Solenoid Test

Neutral Switch Test

Horn Switch Test

Relay Test

Oil Pressure Switch Test

Coolant Temperature Sensor Test

Fuel Shutoff Solenoid Test

Regulated Voltage Output Test

Group 20: Wiring Schematics

Summary of References

Schematic Information

1023E Schematic Legend (S.N. —209999)

1023E Schematic (S.N. —209999)

1023E Schematic Legend (S.N. 210000— )

1023E Schematic (S.N. 210000— )

1026R Schematic Legend (S.N. —209999)

1026R Schematic (S.N. —209999)

1026R Schematic Legend (S.N. 210000— )

1026R Schematic (S.N. 210000— )

1026R EEC Schematic Legend(S.N. —209999)

1026R EEC Schematic (S.N. —209999)

1026R EEC Schematic Legend(S.N. 210000— )

1026R EEC Schematic (S.N. 210000— )

Group 30: Connector Information

Summary of References

K01— K04 Relay Connector

K05— K06 Relay Connector

X03 Power Port Connector

X09 Mow Lift Solenoid Connector

X54 RH Fender Light Connector

X55 LH Fender Light Connector

X—E01 and X—E02 Headlight Connector

X—E01 and X—E02 EEC Headlight Connector

X—G02 Alternator Connector

X—ICC—J1 Display Connector (SN —209999)

X—ICC—J1 Display Connector (SN 210000— )

X—ICC—J1 Display EEC Connector (SN 210000— )

X—ICC—J2 Display Connector (SN —209999)

X—ICC—J2 Display Connector (SN 210000— )

X—ICC—J2 Display EEC Connector (SN 210000— )

X—ICC—J3 Display Connector (SN —209999)

X—ICC—J3 Display Connector (SN 210000— )

X—K07 Flasher Connector

X—M01 Start Motor Connector

X—M02 Fuel Pump Connector

X—R01 Glow Plug Connector

X—S01 Key Switch Connector

X—S02 Light Switch Connector (SN —209999)

X—S02 (X—S08 EEC) Light Switch Connector (SN210000— )

X—S03 Turn Signal Switch Connector

X—S04 Neutral Start Switch Connector

X—S05 PTO Switch Connector (SN —209999)

X—S05 (X—S02 EEC) PTO Switch Connector (SN 210000— )

X—S08 (X—X07) MBR Switch Connector

X—S10 Mow Lift Switch Connector

X—S13 Hazard Switch Connector

X—S38 Seat Switch Connector

X—S40 Front Hitch Detection Connector (SN 210000— )

X—S41 Park Brake Switch Connector

X—S41 Park Brake Switch Connector — EEC

X—S42 Brake Switch Connector

X—S60 Reverse Pedal Sense Connector (SN 210000— )

X—Y02 Fuel Shutoff Solenoid Connector

X—Y03 PTO Solenoid Connector

Section 250: Power Train Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Transmission Sub-Assemblies

Driveshaft

Hydraulic Transmission

Gear Transmission Sub-Assemblies

Transmission Housing

Range Gears, Pinion, and Bevel Gear

Differential

Brakes

Axles

Mechanical Front Wheel Drive (MFWD)

PTO Clutch

PTO Drive

Rockshaft - 1023E

Rockshaft With Feedback - 1026R

Hydraulic Pump and PTO Valve

Front Axle Input Gear and Differential

Front Axle Case and Tie Rod

Front Axle Final Drive Gears

Group 10: Theory of Operation

Summary of References

Gear Train Operation

Range Gear Operation

MFWD Operation

PTO Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Essential or Recommended Tools

MFWD Diagnosis

Adjust Neutral Creep

Adjust Differential Lock

Adjust Forward and Reverse Pedals

Cone Point and Backlash Setting

Section 260: Steering and Brake Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Steering Components

Tilt Steering Components

Brake Components

Park Brake Components - Export

Group 10: Theory of Operation

Summary of References

Steering System Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Adjust Brakes

Adjust Park Brake Engagement

Adjust Park Brake Engagement EEC

Check Toe-in

Section 270: Hydraulic System Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Hydraulic Pump

PTO Solenoid

Group 10: Theory of Operation

Summary of References

Surge Relief Valve Operation

Group 15: Diagnosis

Summary of References

Diagnostic Information

Preliminary Hydraulic System Inspection

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down

Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV

Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV

Remote Cylinder Does Not Extend or Retract

Remote Cylinder Settles Under Load

Remote Cylinder Operates Too Fast or Too Slow

Group 20: Hydraulic Tests

Summary of References

Specifications

Essential or Recommended Tools

Hydraulic Oil Warm-up Procedure

Test SCV Implement Relief Pressure

Test PTO Cluch Pressure

Test HST Charge Pressure

Check Rate of Drop/Stop Valve

Pump Flow Test (Tractors With SCV)

Main Relief Valve Test (Tractors With SCV)

SCV Leakage Test

Rockshaft Lift Cycle Test

Rockshaft Leakdown Test

Group 25: Adjustments

Summary of References

Specifications

Adjust Rockshaft Position Feedback

Adjust Rockshaft Feedback Friction Washers

Group 30: Hydraulic Schematics

Summary of References

Hydraulic Circuit Symbols

1023E Hydraulic Schematic

1026R Hydraulic Schematic

Section 299: Service Tools

Group 05: Dealer Fabricated Tools

Summary of References

PTO Clutch Spring Compression Tool

Group 10: Service Tools and Kits

Essential or Recommended Tools

John Deere 1023E, 1026R Compact Utility Tractors (Worldwide) Service Technical Manual (TM109719)