John Deere Tractors 2204, 7630, 7730, 7830, 7930 Repair Service Manual (TM2266)

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Price: US$ 69.00

John Deere Tractors 2204, 7630, 7730, 7830, 7930 Repair Service Manual (TM2266)

TM2266 - John Deere Tractors 2204, 7630, 7730, 7830, 7930 Technical Manual (Repair).pdf

Complete service repair technical manual for John Deere Tractors 7630, 7730, 7830, 7930 & 2204 (2WD / MFWD), with all the shop information to maintain, repair, service like professional mechanics.

John Deere Tractors 2204, 7630, 7730, 7830, 7930 workshop service 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.
* 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.

Total Pages: 1,943 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General Information
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel / Air Intake and Cooling Systems
      Controls
      Diesel Fuel System
      Air Intake System
      Engine Cooling System
      Hydraulic Oil Cooler and Air Conditioning Condenser/Fuel Cooler
      Exhaust System
   Electrical
      Connectors
      Wiring Harness Routings
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring System
      Armrest Control
      Implement and Accessory Connectors
      Convenience and Accessory Components
   PowrQuad-Plus Transmission
      Component Removal and Installation
      Transmission Shifting Mechanisms
      PowrQuad-Plus Module
      Range Box
   AutoPowr/IVT Transmission
      Component Removal
      Controls
      Front Pump/Control Valve Assembly
      Transmission Front Housing
      Hydrostatic Module
      Shift Valve Assembly
      Transmission Rear Housing
      Differential Input Assembly
   MFWD Drive Systems
      Component Removal And Installation
      Controls
      MFWD Clutch
      MFWD Axle
      Suspended MFWD Axle Components
   Drive Systems
      Component Removal And Installation
      Rear Differential
      Final Drive
      Rear PTO
      Front PTO Repairs
      Primary Brakes
   Steering and Brakes
      Steering Column
      Hydrostatic Steering
      Service Brakes
      Trailer Brakes
   Hydraulics
      Component Removal and Installation
      Hydraulic System Repair
      Hydraulic Pump And Charge Pump
      Hydraulic System Valves
      Selective Control Valves and Couplers
      Rear 3-Point Hitch
      Front 3-Point Hitch
      Bleed Hydraulic System
   Miscellaneous
      Hood
      Front Axle (Two-Wheel Drive)
      Steering Cylinders (Two-Wheel Drive)
      Rear Wheels
      Wagon And Pick-Up Hitch
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Air Suspension Seat
      ACTIVE SEAT™
      Armrest
      Cab Door and Windshield
   Dealer Tools
      Dealer Fabricated Tools
      Essential And Recommended Tools

tm2266 - 76307730783079302204Tractors Repair

Table of Contents

Foreword

Dealer Predelivery Information Form

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

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

Service Tires Safely

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Construct Dealer-Made Tools Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Service Accumulator Systems Safely

Wait Before Opening High-Pressure Fuel System

Servicing Electronic Control Units

Welding Near Electronic Control Units

Live With Safety

Group 10: General Information

List of References

Sealants and Adhesives Cross-Reference Chart

Identify Zinc-Flake Coated Fasteners

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Glossary of Terms

Section 20: Engine

Group 00: Component Removal and Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove and Install Engine

Group 05: Engine Repair

List of References

Specifications

Repair Engine—Use CTM

Access to Front Crankshaft Seal

Access to Rear Crankshaft Seal

Access to Camshaft

Access to Timing Gear Cover

Repair Engine Accessory Drive Assembly

Remove and Install Engine Valve Cover

Section 30: Fuel / Air Intake and Cooling Systems

Group 05: Controls

List of References

Repair Engine—Use CTM

Group 10: Diesel Fuel System

List of References

Specifications

Remove and Install Fuel Tanks

Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Group 15: Air Intake System

List of References

Specifications

Inspect and Service Air Intake System

Group 20: Engine Cooling System

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Test Radiator and Coolant Tank Cap

Remove and Install Radiator

Remove and Install Charge Air Cooler

Inspect Belt Tensioner

Remove and Install Fan Belt

Remove and Install Electronic Fan Drive

Fan Belt Routing

Group 25: Hydraulic Oil Cooler and Air Conditioning Condenser/Fuel Cooler

List of References

Essential, Recommended and Fabricated Tools

Specifications

Other Material

Remove Air Conditioning Condenser/Fuel Cooler

Install Air Conditioning Condenser/Fuel Cooler

Remove and Install Hydraulic Oil Cooler

Leak Test Hydraulic Oil Cooler

Group 30: Exhaust System

List of References

Specifications

Remove and Install Exhaust System

Section 40: Electrical

Group 05: Connectors

List of References

Essential, Recommended and Fabricated Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Repair AMP Connector

Remove Connector Body from Blade Terminals

CINCH CINCH is a trademark of Cinch Inc. Wedgebox Connectors

Exploded View—CINCH Flexbox Connectors

CINCH CINCH is a trademark of Cinch Inc. Flexbox Connectors

Repair CPC CPC is a trademark of AMP Incorporated Blade Type Connectors

Repair CPC CPC is a trademark of AMP Incorporated , Large MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated and METRIMATE METRIMATE is a trademark of AMP Incorporated Pin Type Connectors

Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company Connectors

Repair DEUTSCH™ Implement Connectors

Repair ITT Connector

Repair Small MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated Socket Connector

Repair Small MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated Pin Connector

Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors

Repair (Push Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors

Repair Molex Connector

Repair SUMITOMO™ Connectors

Repair Tyco Fuel Injector Connector

Repair Weather Pack Weather Pack is a trademark of Packard Electric Connector

Repair YAZAKI™ Connectors

Group 10: Wiring Harness Routings

List of References

Wire Number and Color Codes

Ground Point Locations

Positive Battery Cable

Negative Battery Cable

Cab Power Cable

Cab Ground Cable

Cab Harness (PowrQuad PLUS™/AutoQuad PLUS™) (North American)

Cab Harness (PowrQuad PLUS™/AutoQuad PLUS™) (European)

Cab Harness (AutoPowr™/IVT™) (North American)

Cab Harness (AutoPowr™/IVT™) (European)

Right-Hand Console Harness

Right Convenience Outlet Harness

Left Convenience Outlet Harness

Field Office Harness

Auxiliary Power Strip

Operator Control Harness with Manual SCVs (PowrQuad PLUS™/AutoQuad PLUS™)

Operator Control Harness with EH SCVs (PowrQuad PLUS™/AutoQuad PLUS™)

Air Seat Harness

Upper Active Seat Harness

Lower Active Seat Harness

Heated Seat Harness

Manual HVAC Harness

ClimaTrak™ HVAC Harness

SSU Harness (AutoTrac™)

Wheel Angle Sensor Harness (AutoTrac™)

Steering Wheel Position Sensor Harness (AutoTrac™ )

Steering Column Module Harness

JDLink™ Cab Harness

JDLink™ Control Unit Harness

Main Armrest Control Unit Harness (14-Pin)

Standard Armrest Control Unit Harness (20-Pin)

Single Lever Control Assembly Harness

Right Hand Reverser Armrest Control Unit Harness (22 Pin) (AutoPowr™/IVT™ Only)

Left Hand Reverser Armrest Control Unit Harness (22 Pin) (AutoPowr™/IVT™™ Only)

Engine/Chassis Harness with Manual SCVs (Front)

Engine/Chassis Harness with Manual SCVs (Rear)

Engine/Chassis Harness with Manual SCVs, Front Brake, and ILS (Front)

Engine/Chassis Harness with Manual SCVs, Front Brake, and ILS (Rear)

Engine/Chassis Harness with EH SCVs (Front)

Engine/Chassis Harness with EH SCVs (Rear)

Engine/Chassis Harness with EH SCVs, Front Brake, and ILS (Front)

Engine/Chassis Harness with EH SCVs, Front Brake, and ILS (Rear)

Outer Roof Harness

Hood Light Harness (North American)

Hood Light Harness (European)

Hood Light Harness (HID)

Driving Light Extension Harness (European and HID)

Front Roof Inner & Outer Flood Light Harness

Tail Light Harness (European Only)

Extremity Light Harness (North American)

Extremity Light Harness (European)

License Plate Light Harness (European Only)

Beacon Light Harness

Beacon Light Extension Harness

Dual Power Mirror Harness

Front PTO Switch Harness (AutoPowr™/IVT™ Only)

Front PTO/Front Hitch Harness

Front Hitch Switch Extension Harness

Radar Extension Harness

Back-Up Alarm Harness

Electronically Controlled Viscous Clutch Harness

Air Brake Pressure Switch Harness

Rear Brake Pressure Switch Harness

Rear Brake Pressure/Secondary Brake Harness (European Only)

Draft Sensor Extension Harness

Draft/Hitch Position Sensor Harness

Hitch with Manual SCVs Harness

Dual Hitch Switch Harness

Hitch/SCV I Solenoid Harness

SCV II/SCV III Solenoid Harness

SCV IV Solenoid Harness

SCV V/SCV VI Solenoid Harness

Mid Stack Harness

Transmission Harness (PowrQuad PLUS™/AutoQuad PLUS™)

Transmission Harness (AutoPowr™/IVT™)

Group 15: Charging Circuit

List of References

Repair Alternator—Use CTM

Exploded View—Alternator

Remove and Install Alternator

Group 20: Starting Circuit

List of References

Essential, Recommended and Fabricated Tools

Specifications

Repair Starter—Use CTM

Remove and Install Starter Motor

Replace Starter Circuit Relay

Replace Master Fuse

Group 25: Relays, Fuses, Solenoids, and Switches

List of References

Specifications

General Repair Procedures—Solenoids

Load Center Fuses and Relays

Replace Seat Raise/Lower Switch

Replace Seat Firmness Switch (Active Seat)

Replace Heated Seat Switch

Replace Operator Presence Seat Switch

Replace MFWD Switch

Replace MFWD Solenoid

Replace Differential Lock Switch

Replace Rear PTO Shaft Select Switch

Replace Differential Lock and Rear PTO Solenoids

Replace Hitch Raise and Lower Solenoids

Replace Hitch Position Potentiometer Assembly

Replace Clutch Pedal Position Sensor

Remove Electrical Switches, Sensors and Solenoids—PowrQuad-PLUS™ or AutoQuad-PLUS™ Transmissions

Electrical Controls and Switches—AutoPowr™/IVT™ Transmission

Replace AutoPowr™/IVT™ Hydro Control Solenoid

Replace AutoPowr™/IVT™ Fixed Unit Speed Sensor

Replace AutoPowr™/IVT™ Carrier Speed Sensor

Replace Transmission Control (AutoPowr™/IVT™)

Replace SCV Control Lever

Group 30: Monitoring System

List of References

Essential, Recommended and Fabricated Tools

Other Material

Control Units Identification

Replace Control Units

Replace Engine Oil Pressure Sensor

Replace Engine Crank Speed Sensor

Replace Engine Coolant Temperature Sensor

Replace Air Filter Restriction Indicator Sensor

Replace Fuel Level Sensor

Replace Foot Throttle Sensor

Replace Hydraulic Oil Filter Restriction Sensor

Remove and Install Draft Link Sensor

Adjust Draft Link Sensor

Replace Rear PTO Speed Sensor

Replace Radar Sensor

Replace Wheel Angle Sensor (AutoTrac™)

Replace MFWD Speed Sensor—AutoPowr™/IVT™

Replace AutoPowr™/IVT™ Primary Wheel Speed Sensor

Replace AutoPowr™/IVT™ Backup Wheel Speed Sensor

Replace AutoPowr™/IVT™ Transmission Oil Temperature Sensor

Replace AutoPowr™/IVT™ Transmission Pressure Sensor

Replace Instrument Control Unit (CommandCenter™) and SCV Setup Panel (SUP)

Replace Bulbs in Instrument Control Unit (CommandCenter™)

Replace Bulbs In SCV Set-Up Panel (SUP)

Replacing Front Console Display Light Bulbs

Replace Corner Post Display and Bulbs

Group 35: Armrest Control

List of References

Armrest Test Procedures

Replace Armrest Control Assembly

Replace Armrest Control Unit (ACU)

Replace Engine Speed Control

Replace Transmission Control (IVT)

Replace SCV Control Lever

Replace Hitch Control

Replace Rear PTO Switch

Replace IMS Switch

Replace Resume Switch

Group 40: Implement and Accessory Connectors

List of References

Replace Seven-Terminal Outlet Socket

Replace GreenStar™ Terminal Connector

Replace Three-Pin Accessory Outlets

Replace and Adjust Field Lights

Group 45: Convenience and Accessory Components

List of References

Replace Wiper Motor

Replace Windshield Washer Pumps

Replace Circulation Blower Motor

Replace Heating, Ventilating, and Air Conditioning (HVAC) Pressurizer Blower Motor

Test Ground-Fault Circuit Interrupter

Replace Hydraulic Charge Pump Heater

Remove Radio and Speakers

Section 50: PowrQuad-Plus Transmission

Group 00: Component Removal and Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Sealing Instructions—Drive Train

Remove Drive Train

Install Drive Train

Remove Transmission

Install Transmission

Remove Range Box

Install Range Box

Group 05: Transmission Shifting Mechanisms

List of References

Specifications

Reconditioning Shift Lever

Repair Range Shift Linkage (PowrQuad-Plus PowrQuad-Plus is a trademark of Deere & Company Transmissions)

Remove and Install Shift Cables

Check And Adjust Shift Cables (PowrQuad-Plus PowrQuad-Plus is a trademark of Deere & Company Transmissions)

Group 10: PowrQuad-Plus Module

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Replace Temperature Sensor And Pressure Switches

Remove And Install Valves In Front Transmission Cover

Repair Shift Valve Housing

Remove And Install Front Transmission Cover

Remove Hydraulic Pump Drive

Repair Hydraulic Pump Drive

Install Hydraulic Pump Drive

Remove And Install Front Valve Housing

Remove Transmission Oil Pump

Exploded View—Transmission Oil Pump

Repair Transmission Oil Pump

Install Transmission Oil Pump

Remove Gear-Shift Planetary Drive

Exploded View—Planetary Drive

Repair Gear-Shift Planetary Drive

Install Gear-Shift Planetary Drive

Remove B1 Brake Housing

Recondition B1 Brake

Install B1 Brake Housing

Remove B2-B3 Brake Housing

Recondition B2 Brake

Recondition B3 Brake

Install B2-B3 Brake Housing

Remove C4 Clutch

Cross Sectional View—C4 Clutch

Exploded View—C4 Clutch

Repair C4 clutch

Install C4 Clutch

Remove Reverse Brake

Exploded View—Reverse Brake

Repair Reverse Brake

Install Reverse Brake

Remove Forward Clutch With Planetary Drive (Forward/Reverse)

Cross Sectional View—Forward Clutch with Planetary Drive

Exploded View—Forward Clutch with Planetary Drive

Repair Forward Clutch With Planetary Drive (Forward/Reverse)

Install Forward Clutch With Planetary Drive (Forward/Reverse)

Exploded View—Output Shaft

Replace Output Shaft

Group 20: Range Box

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Information—Repair Range Box

Cross Sectional View—Range Box 30 km/h (18 mph)

Cross Sectional View—Range Box 40 km/h (28 mph) and 50 km/h (31 mph)

Exploded View—Input Shaft 30 km/h (18 mph)

Exploded View—Input Shaft 40 km/h (28 mph) and 50 km/h (31mph)

Exploded View—Differential Drive Shaft 30 km/h (18 mph)

Exploded View—Differential Drive Shaft 40 km/h (28 mph) and 50 km/h (31 mph)

Remove Differential Drive Shaft

Remove Input Shaft

Repair Input Shaft

Exploded view—Shifting Mechanism

Exploded View—Park Lock

Install Input Shaft

Adjust Input Shaft End Play

Install Differential Drive Shaft And Adjust Cone Point

Adjust Differential Drive Shaft End Play

Adjust Range Shift

Cross Sectional View—Shifter Assembly

Repair Shift Cover

Replace Speed Sensor

Section 51: AutoPowr/IVT Transmission

Group 00: Component Removal

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove and Install Transmission

Group 05: Controls

List of References

Essential, Recommended and Fabricated Tools

Using Hydraulic Hand Pump to Release Park Brake

Group 10: Front Pump/Control Valve Assembly

List of References

Essential, Recommended and Fabricated Tools

Specifications

Remove, Repair, and Install Hydraulic Pump Drive

General Repair Procedures—Front Control Valve/Transmission Control Pump Assembly

Remove and Install Front Control Valve Assembly

Exploded View—Front Control Valve Assembly

Repair Front Control Valve Assembly

Group 15: Transmission Front Housing

List of References

Essential, Recommended and Fabricated Tools

Specifications

Other Material

General Repair Procedures—Transmission

Hydrostatic Module Replacement

Repair Sequence for Hydrostatic Module Service ONLY

Remove Hydrostatic Module

Install Hydrostatic Module

Group 20: Hydrostatic Module

List of References

Essential, Recommended and Fabricated Tools

Specifications

Exploded View—Hydrostatic Gear Train

Disassemble Hydrostatic Module Gear Train

Repair Hydrostatic Module Gear Train

Assemble Hydrostatic Module Gear Train

Replace Hydrostatic Module

Test Multi-Function Valves

Repair Hydrostatic Module

Group 25: Shift Valve Assembly

List of References

Essential, Recommended and Fabricated Tools

Specifications

General Repair Procedures—Shift Control Valve Assembly

Remove and Install Shift Valve Housing

Exploded View—Shift Valve Housing

Repair Shift Valve Assembly

Service Hi-Lo-Reverse Shift Valves

Air Leak Check Procedure

Group 30: Transmission Rear Housing

List of References

Essential, Recommended and Fabricated Tools

Specifications

Transmission Rear Housing

Cross-Sectional View—Park Brake Assembly

Repair Park Brake

Remove And Install Clutch/Planetary Assembly

Shift Accumulator

Cross Sectional View—Clutch Assembly

Cross Sectional View—Clutch/Planetary Assembly

Exploded View—Planetary Assembly

Repair Clutch/Planetary Assembly

Repair Reverse Brake

Replace Clutch/Planetary Carrier Bearing Cups

Group 35: Differential Input Assembly

List of References

Essential, Recommended and Fabricated Tools

Specifications

General Repair Procedures—Differential Input Assembly

Cross-Sectional View—Differential Input Assembly

Disassemble Differential Input Assembly

Determine Cone Point Shim Pack and Install Differential Drive Shaft

Assemble Differential Input Assembly

Section 56: MFWD Drive Systems

Group 00: Component Removal And Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Sealing Instructions

Remove MFWD Clutch

Install MFWD Clutch

Remove Non-Suspended MFWD Axle

Install Non-Suspended MFWD Axle

Remove Suspended MFWD Axle

Install Suspended Axle

Group 05: Controls

List of References

Specifications

PTO Shift Lever

Group 10: MFWD Clutch

List of References

Essential, Recommended and Fabricated Tools

Specifications

General Repair Procedures—MFWD Clutch

Cross-Sectional View—MFWD Clutch (PowrQuad PLUS™ or AutoQuad PLUS™)

Cross-Sectional View—MFWD Clutch (AutoPowr/IVT)

Disassemble MFWD Clutch

Disassemble MFWD Clutch Pack

Assemble MFWD Clutch Pack

Assemble MFWD Clutch

Group 15: MFWD Axle

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Cross-Sectional View—Planetary Carrier and Wheel Hub Without Brake

Cross-Sectional View—Planetary Carrier and Wheel Hub With Brake

Remove, Recondition, And Install Planetary Carrier And Wheel Hub Without Brake

Remove, Recondition, And Install Planetary Carrier And Wheel Hub With Brake

Cross-Sectional View—Knuckle Spindle Assembly (Standard Duty)

Cross-Sectional View—Knuckle Spindle Assembly (Heavy Duty)

Disassemble, Inspect, and Assemble Knuckle Spindle Assembly

Install Non-Suspended MFWD Axle Into Repair Stand

Install Suspended MFWD Axle Into Repair Stand

Remove And Install Planetary Carrier-Wheel Hub-Knuckle Spindle—U-Joint/Axle Shaft Assembly

Determine Kingpin Shim Pack

Remove Differential Housing

Cross-Sectional View—Differential Housing—Standard Limited Slip Differential

Cross-Sectional View—Differential Housing—Heavy Duty Limited Slip Differential/Suspended Axle

Cross-Sectional View—Differential Housing—Heavy Duty Limited Slip Differential

Cross-Sectional View—Differential Housing—Heavy Duty Limited Slip Differential/Suspended Axle

Cross-Sectional View—Differential Housing—Heavy Duty With Hydraulic Differential Lock

Repair Differential Housing—Limited Slip Differential

Assemble Differential—Limited Slip Differential

Repair Differential Housing—With Hydraulic Differential Lock

Assemble Differential—With Hydraulic Differential Lock

Cross-Sectional View—Differential Drive Shaft and Input Quill—Non-Suspended MFWD Axle

Cross-Sectional View—Differential Drive Shaft And Input Quill—Suspended MFWD Axle

Remove And Disassemble Differential Drive Shaft

Determine Differential Drive Shaft Cone Point Shim Pack

Assemble And Install Differential Drive Shaft

Check Ring Gear Backlash And Determine Differential Case Bearing Cup Shim Pack—Limited Slip

Check Ring Gear Backlash And Determine Differential Case Bearing Cup Shim Pack—Locking

Adjust Ring Gear Backlash

Backlash Shim Pack Example and Worksheet

Install Differential Case Bearing Cup and Differential Housing

Disassemble And Assemble Axle Housing—Standard Duty

Disassemble Axle Housing—Heavy Duty

Determine And Install Axle Housing Bearing Cup Shim Pack—Standard Duty

Determine And Install Axle Housing Bearing Cup Shim Pack—Heavy Duty

Preload Shim Pack Example And Worksheet

Install Axle Housing

Cross-Sectional View—Steering Cylinder Housing Assembly—Non-Suspended MFWD Axle

Cross-Sectional View—Steering Cylinder Housing Assembly—Suspended MFWD Axle

Remove And Disassemble Steering Cylinder

Cross-Sectional View—Steering Cylinder

Assemble And Install Steering Cylinder

Replace MFWD Pivot Bushing

Group 16: Suspended MFWD Axle Components

List of References

Essential, Recommended and Fabricated Tools

Specifications

Exploded View—Suspended Axle Control Valve

Relieve Pressure From Suspended MFWD Axle Hydraulic System

Replace Suspended MFWD Axle Position Sensor

Recondition Suspended MFWD Axle Pressure Control, Pressure Relief, And Solenoid Valves

Cross-Sectional View—Suspended MFWD Axle Cylinder Piston Seals

Check and Charge Accumulators

Exploded View—TLS™ Bearing Support

Remove and Recondition TLS™ Bearing Support

Section 57: Drive Systems

Group 00: Component Removal And Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Sealing Instructions

Remove Front PTO Assembly

Install Front PTO Assembly

Remove Final Drive

Install Final Drive

Remove Rear PTO Assembly

Install Rear PTO Assembly

Group 10: Rear Differential

List of References

Essential, Recommended and Fabricated Tools

Specifications

Rear Differential Repair Instructions

Remove Differential

Rear Differential — Cross Sectional View

Disassemble Differential

Assemble Differential

Adjust Differential Preload

Adjust Differential Backlash

Group 20: Final Drive

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Repair Procedures—Final Drive

Remove Planet Pinion Carrier

Cross-Sectional View—Planet Pinion Carrier

Disassemble Planet Pinion Carrier

Exploded View—Planet Pinion Carrier

Assemble Planet Pinion Carrier

Cross-Sectional View—100 mm Rear Axle Housing And Shaft

Remove Axle Housing

Disassemble And Assemble Axle Housing

Disassemble And Assemble Axle Shaft

Install Axle Housing

Install Planet Pinion Carrier And Check Rolling Drag Torque (Non-Shimmed Axles)

Install Planet Pinion Carrier And Check Rolling Drag Torque (Shimmed Axles)

Group 30: Rear PTO

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Repair Procedures—PTO

Cross-Sectional View—PTO Clutch

Remove And Disassemble PTO Clutch

Assemble And Install PTO Clutch

Remove And Disassemble Output Shaft and PTO Shifter

Remove And Disassemble Countershaft

Cross-Sectional View—Two-Speed Shiftable PTO Countershaft

Cross-Sectional View—Three-Speed Shiftable PTO Countershaft

Assemble And Install Countershaft

Cross-Sectional View—Single-Speed PTO Output Shaft

Cross-Sectional View—Two-Speed Shiftable PTO Output Shaft

Cross-Sectional View—Three-Speed Shiftable PTO Output Shaft

Assemble And Install PTO Output Shaft and PTO Shifter

Exploded View—Shiftable PTO Shifter

Install Shifter

Replace PTO Output Shaft Oil Seal

Remove 540/1000 PTO Adapter Assembly

Disassemble and Assemble 540/1000 PTO Adapter Assembly

Install 540/1000 PTO Adapter Assembly

Group 35: Front PTO Repairs

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Repair Procedures—PTO

Remove and Install Front PTO Driveline

Exploded View—Front PTO Driveline

Repair Front PTO Driveline

Remove and Install Front PTO Oil Cooler

Remove and Install Front PTO Pump

Remove Front PTO Clutch Housing

Disassemble Front PTO Clutch Housing

Assemble Front PTO Clutch Housing

Replace Front PTO Brake

Remove Front PTO Output Shaft

Install Front PTO Output Shaft

Remove and Install Modulating Valve

Repair Pressure Regulating Valve

Repair Oil Cooler Bypass and Lube Relief Valves

Disassemble Front PTO Gearcase Housing

Group 40: Primary Brakes

List of References

Essential, Recommended and Fabricated Tools

Remove and Install Brake Plates, Disks, and Pistons

Section 60: Steering and Brakes

Group 05: Steering Column

List of References

Remove Cowl and Plenum

Repair Steering Column (Standard and AutoTrac)

Replace Clutch Pedal Return Spring

Group 10: Hydrostatic Steering

List of References

Specifications

Remove and Install Steering Control Assembly (Standard and AutoTrac)

Group 15: Service Brakes

List of References

Essential, Recommended and Fabricated Tools

Service Parts Kits

Specifications

General Repair Procedures—Brake Valve

Remove and Install Brake Valve

Disassemble, Inspect, and Assemble Brake Valve

Bleed MFWD Brakes

Bleed Brakes

Power-Assisted Brake Capacity Test

Manual Brake Capacity Test (Engine OFF)

Group 20: Trailer Brakes

List of References

Specifications

Air Brake Supply System

Air Brake Single Line System Component Location

Air Trailer Brake System Component Location (North American)

Air Brake Component Location (Western Europe)

Remove and Install Air Compressor

Hydraulic Trailer Brake Component Location

Section 70: Hydraulics

Group 00: Component Removal and Installation

List of References

Specifications

Remove and Install Hydraulic Pump

Remove And Install Hitch Valve

Remove and Install Deluxe SCVs

Remove and Install Mid-Stack

Remove and Install SCV Valve Stack and Couplers

Group 05: Hydraulic System Repair

List of References

Essential, Recommended and Fabricated Tools

Specifications

General Repair Procedures—Hydraulic System

Use Special Wrench

Install Hydraulic Fittings

Group 10: Hydraulic Pump And Charge Pump

List of References

Other Material

Specifications

Remove And Install Hydraulic Pump Controller

Repair Hydraulic Pump Controller

Exploded View—Hydraulic Charge Pump

Group 15: Hydraulic System Valves

List of References

Essential, Recommended and Fabricated Tools

Specifications

General Repair Procedures—Hitch and Inlet-Priority Valves

Disassemble, Inspect, and Assemble Inlet-Priority Valve

Exploded View—Hitch Valve

Disassemble, Inspect, and Assemble Hitch Valve

Test Surge Relief Valve

Group 20: Selective Control Valves and Couplers

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Repair Procedures—Selective Control Valves

Remove, Install, And Adjust Cables—Manual SCV

Exploded View—Manual Selective Control Valve (Three-Postion)

Replace Control Knob—Manual SCV

Inspect Poppet Load-Check Valves—Manual SCV

Inspect Pressure Compensator Valve—Manual SCV

Inspect Metering Valve—Manual SCV

Disassemble, Inspect, And Assemble Control Valve—Manual SCV

Exploded View—Manual Selective Control Valve (Single-Position)

Disassemble, Inspect, And Assemble Control Valve (Manual SCV-Single Position)

Exploded View—Deluxe SCV

Repair Deluxe SCVs

Rear Hydraulic Couplers (Deluxe)—Repair

Remove and Install Mid-Stack Couplers

Remove and Install (Late Model) Mid-Stack Couplers

Disassemble and Assemble Mid-Stack

Repair Directional Valve

Group 30: Rear 3-Point Hitch

List of References

Essential, Recommended and Fabricated Tools

Specifications

Remove and Install Hitch Lift Cylinders

Remove and Install Rockshaft Support Housing

Remove and Install Rockshaft

Replace Rockshaft Housing Bushings

Repair Draft Sensing Shaft

Cross-Sectional View—Lift Cylinder

Disassemble, Inspect, and Assemble Lift Cylinder

Group 35: Front 3-Point Hitch

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove and Install Front 3-Point Hitch

Exploded View—Front 3-Point Hitch

Exploded View—Front Hitch Lift Cylinder

Repair Front Hitch Lift Cylinder

Group 40: Bleed Hydraulic System

List of References

Essential, Recommended and Fabricated Tools

Bleed Hydraulic System

Section 80: Miscellaneous

Group 05: Hood

List of References

Specifications

Remove and Install Hood

Group 10: Front Axle (Two-Wheel Drive)

List of References

Essential, Recommended and Fabricated Tools

Specifications

Other Material

Remove Front Axle (Two-Wheel Drive)

Install Front Axle (Two-Wheel Drive)

Replace Knee Bushings

Replace Wheel Bearings

Group 15: Steering Cylinders (Two-Wheel Drive)

List of References

Other Material

Service Parts Kits

Specifications

Remove and Install Steering Cylinder (Two-Wheel Drive)

Cross-Sectional and Exploded View—Steering Cylinder—Two-Wheel Drive

Group 20: Rear Wheels

List of References

Essential, Recommended and Fabricated Tools

Specifications

Service Heavy-Duty Wheel Clamps

Group 25: Wagon And Pick-Up Hitch

List of References

Specifications

Repair Wagon Hitch

Adjust Wagon Hitch Release

Repair Pick-Up Hitch

Adjust Pick-Up Hitch

Section 90: Operator Station

Group 00: Component Removal and Installation

List of References

Essential, Recommended and Fabricated Tools

Specifications

Remove Cab

Install Cab

Repair Cab

Group 05: Heating, Ventilating, and Air Conditioning (HVAC)

List of References

Heater Line Routing

Remove HVAC Module

Install HVAC Module

Remove and Install Heater Core

Remove and Install Heater Control Valve (Without CLIMATRAK)

Remove and Install Heater Control Valve (With CLIMATRAK)

Leak Test Manual Heater Control Valve

Install Heater Control Valve

Remove and Install Control Cable

Adjust Heating/Cooling Controls

Group 10: Air Conditioning System

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Repair Air Conditioning System—Use CTM

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Discharge Air Conditioning System

Flushing, Purging, and Evacuating Information

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

Add Refrigerant Oil to Pressurized System

Remove and Install Compressor

Test Volumetric Efficiency

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

Replace Receiver-Dryer

Remove and Install Expansion Valve

Remove Air Conditioning Condenser

Leak Test Condenser

Leak Test Evaporator

Remove and Install Evaporator

Group 15: Air Suspension Seat

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove and Install Seat

Repair Seat Air System

Repair Seat Suspension

Repair Seat Back

Repair Seat Control Knobs

Group 20: ACTIVE SEAT™

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Purging Air from ACTIVE SEAT ACTIVE SEAT is a trademark of Deere & Company System

Remove and Install ACTIVE SEAT ACTIVE SEAT is a trademark of Deere & Company

Remove and Install ACTIVE SEAT™ Actuator

Remove and Install Actuator Hoses

Remove and Install Seat Control Valve Assembly

Exploded View—ACTIVE SEAT™ Hydraulic Control Valve Block

Remove and Install Accumulator

Checking and Charging Replacement Accumulators

Repair ACTIVE SEAT™ Air System

Repair ACTIVE SEAT™ Suspension

Repair Seat Back

Group 25: Armrest

List of References

Remove and Install Armrest Control

Disassemble and Assemble Armrest Adjustment Assembly

Group 30: Cab Door and Windshield

List of References

Specifications

Repair Cab Door Latch

Cab Door Adjustment—Step 1

Cab Door Adjustment—Step 2

Cab Door Adjustment—Step 3

Cab Door Adjustment—Step 4

Cab Door Adjustment—Step 5

Replace Windshield Glass or Seal

Section 99: Dealer Tools

Group 05: Dealer Fabricated Tools

List of References

DF1057—Axle Adjusting Tool

DFRW4—Axle Wheel Hub Tool

DFRW20—Compressor Holding Fixture

DFRW30A—Axle Jacking Tool

DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses

DFRW70—Holding Tool

DFRW87—Pick-Up Hitch Adapter Plate

DFRW92—Mounting Guide Pins

DFRW94—Rear Axle Support Stand

DFRW98—Rear Axle Guide Pin

DFRW99—540/1000 PTO Adapter Assembly Bearing Installer

DFRW132—Differential Side Bevel Gear End Play Tool

DFRW139—Evaporator Flushing Block

DFRW148—ActiveSeat™ Control Valve Holding Tool

DFRW151—Radiator Cap Adapter

DFRW156—Shift Valve Bore Flushing Can

DFRW168—Park Brake Solenoid Harness

DFRW178 — Front Brake Bleed Wrench

DFRW179—Front PTO Support Bracket

DFRW182—Cone Stand Adapter

DFRW193—Modification to JT07130 Rear PTO Removal Bracket to a JT07130A

DFRW194—MFWD Input Shaft Holding Tool

DFRW212 Leak Test Assembly

DFRW213 — Hydraulic Trailer Brake Test / Bleed Assembly

Group 10: Essential And Recommended Tools

List of References

D01006AA Bench-Mounted Holding Fixture

D01044AA Bushing, Bearing and Seal Driver Set

D01045AA Disk Set

D01047AA 17-1/2 and 30 Ton Hydraulic Puller Set

D01048AA 17-1/2 Hydraulic Puller Set

D01061AA Blind-Hole Puller Set

D01173AA 17-1/2 Ton Mechanical Puller Set

D01290AA Push-Puller

D01301AA Internal Puller

D05072ST Transmission Plate

D05104ST Radiator Pressure Tester

D05117ST Spanner Wrench

D05223ST Engine Rollover Stand

D05277ST Pulley Remover

D05361ST Rubber Stopper and Leak Detector Kit

JDG19 Lifting Eyes

JDG23 Lift Sling

JDG135 Driver Disk (140 mm or 5-1/2 in.)

JDG141 Extraction Tool

JDG155 Electrical Repair Tool Kit

JDG215 Compressor Seal and Clutch Repair Kit

JDG226 Special Hex Drive

JDG303 Clutch Spring Washer Compressor

JDG359 DEUTSCH Electrical Repair Tool Kit

JDG537 Driver Handle

JDG652-1 Bearing Installer

JDG658 Special Hydraulic Wrench

JDG707 Crimping Tool

JDG708 AMP Crimping Tool

JDG731A Spanner Socket

JDG746 Compressor Seal Protector

JDG747 A/C Compressor Clutch Spanner

JDG748 Jaws

JDG749 54-Inch Extension

JDG750 Swivel Socket

JDG753 PTO Seal Installer

JDG754 Spring Compressor

JDG755 Bushing Installer

JDG761 Seal Installer

JDG765 Bushing Installer

JDG766 Clip Removal Tool

JDG768 Pilot Pins

JDG770 Seal Installer

JDG771 Forcing Screw Pilot

JDG772 Input Planetary Installation Tool

JDG775 Seal Installer

JDG778A Rolling Drag Torque Tool

JDG783 Weather Pack Crimping Tool

JDG789 Hydraulic Test Adapter

JDG811 Puller

JDG820 Flywheel Rotation Tool

JDG839 Radiator Pressure Tester Adapter

JDG851 Seal Installer

JDG855 Clutch Assembly Tool

JDG865 Crimping Tool

JDG867 Axle Seal Installer

JDG882 Mounting Guide Pins

JDG890A Planetary Carrier Lifting Tool

JDG928 Spanner Wrench

JDG948 Terminal Extractor Tool

JDG983 Snap Ring Expander Tool

JDG1076 Cone Stand and Adapter

JDG1076A Cone Stands and Adapters

JDG1090 Yoke Holding Tool

JDG1123 Driver Disk

JDG1182 Puller Adapter

JDG1198 Bearing Installer

JDG1209 Axle Support Bracket

JDG1211 Bushing Installer Pilot

JDG1212 Bushing Remover

JDG1213 Tie Rod Wrench

JDG1214 Steering Cylinder Rod Wrench

JDG1215 Bearing Cup Installer Set

JDG1216 Ring Gear Holding Tool

JDG1217 Differential Housing Tool Set

JDG1218A Seal Installer

JDG1219 Seal Installer

JDG1220 Spacer Installer

JDG1221 Seal Installer Set

JDG1222 Puller Jaws

JDG1224 Special Socket

JDG1227 Suspended Axle Cylinder Tool Set

JDG1253 Spanner Socket

JDG1255 Slinger-Seal Installer

JDG1272 Bushing-Seal Installer

JDG1419 Lifting Bridle

JDG1424 Support Block

JDG1504 IVT Hi-Lo-Reverse Shift Valve Service Tool Kit

JDG1505 Test Block

JDG1506 Anti-Rotation Tool

JDG1507 Attaching Bracket

JDG1509 Holding Fixture

JDG1510 Spring Compressor Brackets

JDG1511 Park Brake Service Tools

JDG1512 Clutch Spring Compressor

JDG1513 Control Tube Remover

JDG1514 Guide

JDG1579 Coupler Tool

JDG1655A Lifting Bracket

JDG1662 Spacer Ring

JDG1666 Park Brake Release Hand Pump Kit

JDG1670 Axle Support Bracket

JDG1707 Axle Lifting Bracket

JDG1744 Master Repair Kit

JDG1769 Differential Housing Tool Set

JDG1826 Seal Driver

JDG1827-1 PTO Seal Installer

JDG1827-2 PTO Seal Driver Spud

JDG1827-3 PTO Seal Driver Spud

JDG1885 Snap-to-Connect Release Tools

JDG2046 Starter Wrench

JDG10145 Terminal Crimping Tool

JDG10146 Extraction Tool

JDG10198 Terminal Crimping Tool

JDG10207 Spanner Socket

JDG10208 Transmission Shift Valve Tool

JDG10211 Seal Installer

JDG10353 DEUTSCH Crimp and Extractor Tool Set

JDG10927 Terminal Extraction Tool

JDG11016 Die Assembly

JDG11017 Crimper Tool

JDG11019 Extractor Tool

JDG-PST Power Shift Transmission Repair Kit

JDT32 Seal Installer Disk

JDT44 2-1/2 in. Heavy Duty Socket

JT01673 Bearing Cup Installer

JT01778 Threaded Adapter (5/8 in. x 12 mm)

JT02045 Recovery/Recycling, and Charging Station

JT02050 Recovery/Recycling Station

JT02051 Manifold with Gauges

JT02063 Electronic Leak Detector

JT02075 Air Conditioning Flushing Unit

JT02081 Electronic Leak Detector

JT02098 Air Conditioning Fitting Kit

JT02129 Air Conditioning Oil Injector

JT02147 Tube Fitting

JT03474 — Male-to-Male Quick Coupler

JT03515 Accumulator Charging Set

JT05412 Universal Pressure Test Kit

JT05471 Gauge w/Quick Coupler, 7000 kPa (70 bar) (1000 psi)

JT05508 Lift Eye

JT05563 Nitrogen Charging Hose

JT05726 Wheel and Axle Lift

JT07045 Hydraulic Pressure Gauge

JT07056 Service Jack

JT07115 Master Hydraulic Kit

JT07118 — Two-Valve Manifold

JT07119 Test Hose

JT07122 Splitting Stand

JT07122-3 Splitting Stand Adapter

JT07122-10 Splitting Stand Support Adapter Kit

JT07122-11 Bushing Collar Adapter

JT07130A PTO Housing Lifting Fixture

JT07131A Differential Lifting Tool

JT07134 — Bleed Pipe

JT07195B Technician’s Electrical Repair Kit

JT07208 Hydraulic Fitting Kit

JT07218 Rear Axle Lifting Tool

JT07219 Rear Axle Support Stand

JT07359 Splitting Stand “L” Brackets

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