Complete Repair Service Technical Manual for John Deere 8120T, 8220T, 8320T, 8420T & 8520T Tracks Tractors, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere Tracks Tractors 8120T, 8220T, 8320T, 8420T & 8520T workshop technical manual (repair) 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.

tm1971 - 8120T, 8220T, 8320T, 8420T and 8520T Tractors Repair Technical Manual.pdf
tm1971 - 8120T, 8220T, 8320T, 8420T and 8520T Tractors Repair Technical Manual.epub

Total Pages: 1,214 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General Information
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel and Cooling Systems
      Diesel Fuel System
      Air Intake System
      Engine Cooling System
      Coolers and Air Conditioning Condenser
   Electrical
      Connectors
      Wiring Harness Routings
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring Systems and Sensors
      Armrest Control
      Implement and Accessory Connectors
      Convenience and Accessory Components
   Transmission
      Component Removal and Installation
      In-Tractor Repair
      Transmission
   Drive Systems
      Component Removal and Installation
      Rear Axle Assembly
      Outboard Planetary Final Drive
      PTO
      Steering Gears
      Mid-Frame Drive Shafts
   Steering and Brakes
      Component Removal and Installation
      Steering Column
      Steering Wheel Position Input Assembly
      Steering Pump
      Steering Motor
      Brake Valve
      Brake Components
   Hydraulics
      Component Removal and Installation
      Hydraulic System Repair and Cleanup
      Tandem Hydraulic Pump (Transmission Control-Charge)
      Secondary Hydraulic Pump (Hitch-SCV)
      Hydraulic Filter Bypass
      Hitch Valve, Selective Control Valves, and Couplers
      Hitch
   Miscellaneous
      Hood
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Air Suspension Seat
      Armrest
      Cab Door and Windshield
   Track Frame and Components
      Tracks
      Tension Cylinder and Accumulator
      Track Frame
   Dealer Fabricated Tools
      Fabricated Tools

tm1971 - 8120T, 8220T, 8320T, 8420T and 8520T Tractors 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

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

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Construct Dealer-Made Tools Safely

Dispose of Waste Properly

Live With Safety

Group 10: General Information

General Specifications

Overall Dimensions

Sealants and Adhesives Cross-Reference Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Glossary of Terms

Section 20: Engine

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Remove Engine

Install Engine

Remove Front Frame

Install Front Frame

Group 05: Engine Repair

Engine Repair—Use CTM86 or CTM255

Section 30: Fuel and Cooling Systems

Group 05: Diesel Fuel System

Remove and Install Fuel Fill Tank

Remove and Install Main Fuel Tank

Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Group 10: Air Intake System

Specifications

Other Material

Service Air Intake System

Repair Aspirator

Group 15: Engine Cooling System

Essential or Recommended Tools

Specifications

Test Radiator and Coolant Tank Cap

Remove and Install Radiator/Aftercooler

Auxiliary Drive Belt Routing

Inspect Tensioner

Repair Variable Fan Drive Assembly

Remove and Install Vistronic Fan Drive—8520T

Group 20: Coolers and Air Conditioning Condenser

Essential or Recommended Tools

Specifications

Other Material

Remove Air Conditioning Condenser

Install Air Conditioning Condenser/Fuel Cooler

Replace Hydraulic Oil Cooler

Leak Test Hydraulic Oil Cooler

Section 40: Electrical

Group 05: Connectors

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Repair AMP Connector

Remove Connector Body from Blade Terminals

Repair CINCH 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 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 SUMITOMO™ Connectors

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

Repair YAZAKI™ Connectors

Group 10: Wiring Harness Routings

Wire Number and Color Codes

Ground Point Locations

#1 Cab Ground (Roof)

#2 Cab Ground (Floor)

# 3 Chassis (Single Point Ground)

Miscellaneous Grounds

Main Chassis Harness Routing and Component Identification

Cab Harness Routing and Component Identification—North American

Cab Harness Routing and Component Identification—European

Transmission Harness Routing and Component Identification

Pump Drive Housing Harness Routing

Roof Harness Routing and Component Identification

Remote Mirror Harness Routing and Component Identification

GREENSTAR GREENSTAR is a trademark of Deere & Company Harness Routing and Component Identification

Battery Cable Routing

Starter and Alternator Power Cable Routing

Group 15: Charging Circuit

Repair Alternator—Use CTM77

Disconnect Electrical Circuit

Exploded View—Alternator

Replace Alternator

Group 20: Starting Circuit

Essential or Recommended Tools

Specifications

Repair Starter—Use CTM

Disconnect Electrical Circuit

Remove and Install Starter Motor

Replace Fusible Link

Replace Starter Circuit Relay

Replace Neutral Start Switch

Group 25: Relays, Fuses, Solenoids, and Switches

Essential or Recommended Tools

Other Material

Specifications

General Repair Procedures—Solenoids

Disconnect Electrical Circuit

Load Center Fuses—North America

Load Center Fuses—European

Load Center Relays and Diodes—North America

Load Center Relays and Diodes—European

Replace Starting Aid Solenoid

Replace Electro-Hydraulic Shift Valve Solenoids

Replace Park Brake Release Solenoid

Replace PTO Electro-Hydraulic Valve

Replace SCV Solenoids

Replace Hitch Valve Solenoids

Replace Engine Oil Pressure Switch

Replace Air Filter Restriction Switch

Replace Transmission Manifold Electrical Switches

Exploded View—Right Console Controls and Switches

Replace Right Console Switches

Replace Dome Light Switch

Replace Cab Door Light Switch

Replace Beacon Light Switch

Replace Starting Aid and Ignition Switch

Replace Seat Raise/Lower Switch

Replace Operator Presence Seat Switch

Replace Brake Light Switch

Replace Hand Brake Switch and Potentiometer—European

Replace Hydraulic Clean-Oil Reservoir Level Switch

Replace External Hitch Raise/Lower Switches

Replace A/C High- and Low-Pressure Switch

Replace A/C Deicing Switch and Blower Motor Resistor

Group 30: Monitoring Systems and Sensors

Essential or Recommended Tools

Other Material

Specifications

Disconnect Electrical Circuit

Replace Instrument Control Unit and SCV Set-up Panel

Replace Bulbs in Instrument Control Unit (ICU)

Replace Bulbs SCV Set-Up Panel (SUP)

Replace Corner Post Display and Bulbs

Replace Steering Column Module Bulbs

Replace Steering Column Module

Control Units and Component Identification

Replace Control Units

Replace EEPROM EEPROM—Electrically Erasable Programmable Read-Only Memory In Control Units

Remove EEPROM

Install Replacement EEPROM

Replace Engine Coolant Temperature Sensor

Replace Engine Crank Speed Sensor

Replace Fuel Level Sensor

Replace Fuel Temperature Sensor

Replace Air Intake Temperature Sensor

Replace Foot Throttle Sensor

Replace Track Tension Pressure Sensor

Replace Wheel Speed Sensor

Replace Radar Speed Sensor

Replace PTO Speed Sensor

Replace Steering Motor Speed Sensor

Replace Steering Filter Oil Restriction Sensor

Replace Hydraulic Oil Filter Restriction Sensor and Temperature Sensor

Replace Hitch Position Sensor

Replace Draft Sensing Sensor

CLIMATRAK CLIMATRAK is a trademark of Deere & Company Wire Harness and Component Identification

Replace Outlet Duct Temperature Sensor

Replace Cab Temperature Sensor

Replace Fresh Air Temperature Sensor

Replace Evaporator Temperature Sensor

Group 35: Armrest Control

Disconnect Electrical Circuit

Armrest Test Procedures

Replace Armrest Control Assembly

Replace Armrest Control Unit (ACU)

Exploded View—Armrest Control

Replace Armrest Controls

Exploded View—Engine Speed Control

Exploded View—Transmission Control

Exploded View—SCV Control Lever

Replace Hitch Control

Group 40: Implement and Accessory Connectors

Replace Seven-Terminal Outlet Socket

Replace GREENSTAR GREENSTAR is a trademark of Deere & Company Terminal Connector

Replace Three-Pin Accessory Outlets

Diagnostic/Program Connector

Replace and Adjust Field Lights

Group 45: Convenience and Accessory Components

Replace Circulation Blower Motor

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

Replace Seat Air Compressor Motor

Replace Wiper Motors

Replace Windshield Washer Pumps

Replace Hydraulic Charge Pump Auxiliary Heater

Replace Transmission Auxiliary Heater

Remove Radio and Speakers

Section 50: Transmission

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Transmission

Install Transmission

Remove Scavenge Pump

Install Scavenge Pump

Remove Ground-Driven Pump

Install Ground-Driven Pump

Group 05: In-Tractor Repair

Essential or Recommended Tools

Other Material

Specifications

Disengage Park Brake

Replace Transmission Input Shaft Front Seal

Replace Auxiliary Drive Pulley

Replace Transmission Input Shaft Rear Seal—Transmission in Tractor

Repair Clutch Pedal

Replace Clutch Cable

Replace Clutch Operating Spring

Group 10: Transmission

Essential or Recommended Tools

Other Material

Specifications

Clutch Cover Plate Orientation

General Repair Procedures—Power Shift Transmission

Install Transmission in Repair Stand

Cross-Sectional View—Transmission Assembly

Disassemble Transmission

Exploded View—Manifold Valves

Remove and Install Manifold Valves

Cleaning Procedures—Manifold, Rear Cover, and Valves

Disassemble and Assemble Manifold

Inspect and Clean Electro-Hydraulic Valves

Disassemble and Assemble Manifold

Disassemble and Assemble Transmission Rear Cover

Cross-Sectional View—Transmission Input Shaft

Disassemble Input Shaft

Assemble Input Shaft Gear/Clutch Assemblies

Assemble Input Shaft

Cross-Sectional View—Transmission Countershaft

Disassemble Countershaft

Assemble Countershaft Gear/Clutch Assemblies

Assemble Countershaft Gear/Clutch Assemblies

Assemble Countershaft

Cross-Sectional View—Transmission Output Shaft

Disassemble Output Shaft Assembly

Disassemble, Inspect, and Assemble Planetary Carrier

Inspect Clutch Disks

Assemble Output Shaft Assembly

Assemble Transmission

Remove Transmission From Repair Stand

Section 56: Drive Systems

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Rear Axle Assembly

Install Rear Axle Assembly

Remove Outboard Planetary Final Drive Assembly

Install Outboard Planetary Final Drive Assembly

Group 05: Rear Axle Assembly

Essential or Recommended Tools

Other Material

Specifications

Remove Input Gears

Disassemble and Assemble Input Shaft/Gear Assembly

Disassemble and Assemble Pump Drive Gear

Install Pump Drive Housing Oil Baffle Screen

Install Input Gears

Cross-Sectional View—Input Shaft

Adjust Input Shaft Bearing Preload

Remove and Install Pump Drive Housing

Cross-Sectional View—Spiral Bevel Pinion Shaft

Disassemble and Recondition Spiral Bevel Pinion Shaft

Determine Spiral Bevel Pinion Shaft Cone Point Shim Pack

Assemble and Install Spiral Bevel Pinion Shaft

Cross-Sectional View—Spiral Bevel Ring Gear Assembly

Remove and Recondition Spiral Bevel Ring Gear Assembly

Install Spiral Bevel Ring Gear Assembly

Side Quill Adjustment Information

Adjust Carrier Assembly Bearing Preload

Adjust Spiral Bevel Ring Gear Backlash

Group 10: Outboard Planetary Final Drive

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—Final Drive Outboard Planetary Carrier

Remove Outboard Planetary Carrier

Recondition Outboard Planetary Carrier

Cross-Sectional View—Standard and Narrow Tread Housing Assembly

Cross-Sectional View—Wide Tread Housing Assembly

Recondition Axle Housing Assembly

Establish Axle Bearing Preload

Assemble Axle Housing

Group 15: PTO

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—PTO Assembly

Remove PTO Clutch

Cross-Sectional View—PTO Clutch Assembly

Recondition PTO Clutch

Install PTO Clutch

Remove and Install PTO Output Housing Assembly

Cross-Sectional View—PTO Output Housing Assembly

Recondition PTO Output Housing

Remove PTO Clutch Valve

Group 20: Steering Gears

Essential or Recommended Tools

Other Material

Specifications

Remove Steering Planetary, Ring Gear, and Sun Gear

Recondition Steering Planetary

Install Steering Planetary, Ring Gear, and Sun Gear

Remove, Recondition, and Install Steering Idler Gears

Remove, Recondition, and Install Steering Motor Output Gear

Remove, Recondition, and Install Cross Shaft Gear Assembly

Group 25: Mid-Frame Drive Shafts

Essential or Recommended Tools

Specifications

Cross-Sectional View—Mid-Frame Drive Shafts

Remove and Install Drive Shafts

Section 60: Steering and Brakes

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Install Hydraulic Fittings

Remove and Install Steering Pump

Remove and Install Steering Motor

Flush Steering System

Group 05: Steering Column

Specifications

Repair Steering Column

Group 10: Steering Wheel Position Input Assembly

Specifications

Remove and Install Steering Wheel Position Input Assembly

Repair Steering Wheel Position Input Assembly

Group 15: Steering Pump

Essential or Recommended Tools

Service Parts Kits

Specifications

Exploded View—Steering Charge Pump and Pump Control

Disassemble, Inspect, and Assemble Steering Charge Pump

Disassemble, Inspect, Assemble Displacement Control Valve

Exploded View—Steering Pump

Disassemble, Inspect, and Assemble Hydraulic Steering Pump

Group 20: Steering Motor

Essential or Recommended Tools

Service Parts Kits

Specifications

Exploded View—Steering Motor

Disassemble, Inspect, and Assemble Steering Motor

Group 25: Brake Valve

Service Parts Kits

Specifications

General Repair Procedures—Brake Valve

Remove and Install Brake Valve

Disassemble, Inspect, and Assemble Brake Valve

Adjust Brake Pedal

Adjust Secondary Brake

Bleed Brakes

Check Manual Brakes

Group 30: Brake Components

Specifications

Remove, Inspect, and Install Brake Components

Section 70: Hydraulics

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Tandem Pump

Remove and Install Secondary Pump

Remove and Install Hitch-SCV Valve Stack

Group 05: Hydraulic System Repair and Cleanup

Essential or Recommended Tools

Specifications

Other Material

General Repair Procedures—Hydraulic Systems

Install Hydraulic Fittings

Drain Hydraulic System

Prelubricate, Fill, and Startup Hydraulic System

Conditions Requiring Hydraulic System Cleanup

Hydraulic Cleanup Procedure

Group 10: Tandem Hydraulic Pump (Transmission Control-Charge)

Replace Shaft Seal

Group 15: Secondary Hydraulic Pump (Hitch-SCV)

Essential or Recommended Tools

Specifications

Other Material

Service Parts Kits

Pump Identification

Replace Shaft Seal—45 cm3 Pump

Service Hydraulic Pump Control—45 cm3 Pump

Repair Hydraulic Pump—45 cm3 Pump

Service Hydraulic Pump Control—57 cm3 Pump

Exploded View—57 cm3 Pump

Replace Pump Shaft Seal—57 cm3 Pump

Disassemble and Inspect Pump—57 cm3 Pump

Assemble Hydraulic Pump—57 cm3 Pump

Group 20: Hydraulic Filter Bypass

Service Parts Kits

Specifications

Remove, Inspect, and Install Hydraulic Filter Housing

Group 25: Hitch Valve, Selective Control Valves, and Couplers

Essential or Recommended Tools

Specifications

Disassemble and Assemble Hitch-SCV Valve Stack

Disassemble, Inspect, and Assemble Hitch Valve

Test High Pressure Relief Valve

Disassemble, Inspect, and Assemble Selective Control Valve

Repair SCV Couplers

Group 30: Hitch

Essential Tools

Other Material

Specifications

Remove and Install Lift Cylinder

Cross-Sectional and Exploded View—Hitch Lift Cylinder

Disassemble, Inspect, and Assemble Lift Cylinder

Replace Rockshaft Bushings

Repair Draft Sensing

Section 80: Miscellaneous

Group 05: Hood

Position Hood Forward

Remove and Install Hood

Section 90: Operator Station

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Remove Cab

Install Cab

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

Heater Line Routing

Remove HVAC Module

Install HVAC Module

Remove and Install Heater Core

Remove and Install Heater Control Valve (Without CLIMATRAK ClimaTrak is a trademark of Deere & Company )

Remove, Test, and Install Heater Control Valve (With ClimaTrak ClimaTrak is a trademark of Deere & Company )

Leak Test Heater Control Valve

Install Heater Control Valve

Remove and Install Control Cable

Adjust Heating/Cooling Controls

Group 10: Air Conditioning System

Essential or Recommended Tools

Other Material

Specifications

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Diagram—Air Conditioning System

Reference Chart—Fittings—Air Conditioning System

Leak Test With Dye

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

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Seat

Repair Air System

Repair Suspension

Repair Seat Back

Repair Control Knobs

Group 25: Armrest

Remove and Install Armrest Control

Disassemble and Assemble Armrest Adjustment Assembly

Group 30: Cab Door and Windshield

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 95: Track Frame and Components

Group 05: Tracks

Essential or Recommended Tools

Specifications

Detension and Tension the Track

Track Alignment

Adjust Track Tread Settings

Remove and Install Track

Group 10: Tension Cylinder and Accumulator

Essential or Recommended Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Track Tension Cylinder

Cross-Sectional and Exploded View—Track Tension Cylinder

Disassemble, Inspect, and Assemble Track Tension Cylinder

Precharge Tension Accumulator

Group 15: Track Frame

Essential or Recommended Tools

Other Material

Specifications

Exploded View—Axle Brace (Wide Axle)

Remove and Install Axle Brace (Wide Axle)

Replace Tension Link Bushings

Remove, Recondition, and Install Front Idler Hub

Remove, Recondition, and Install One Piece Mid-Roller Assembly

Remove, Repair, and Install Two Piece Mid-Roller Assembly

Section 99: Dealer Fabricated Tools

Group 05: Fabricated Tools

Fabricated Tools

DFRW2—Needle Valve Test Hose Assembly

DFRW7—Differential Lifting Tool

DFRW20—Compressor Holding Fixture

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

DFRW89—Transmission Shaft and Clutch Holding Fixture Tool may be purchased. Order JT07203

DFRW90—Transmission Support Plate

DFRW91—Guide Pins

DFRW92—Mounting Guide Pins

DFRW93—Auxiliary Drive Support Bracket Tool may be purchased. Order JDG860

DFRW97—Transmission Countershaft Rotation Screw

DFRW111—Flushing Wand Tool may be purchased. Order JT03501

DFRW112—Transmission Flushing Shift Valves

DFRW117—Transmission-Hydraulic Flusher

DFRW123—Steering Motor Bypass Hose

DFRW129—STEERING MOTOR SENSOR GAUGE

DFRW136—STEERING PUMP REMOVAL TOOL

DFRW139—Thermal Expansion Valve Replacement Tool

DFRW144—European Narrow Rear Axle Lift Tool

DFRW150—SCV-Hitch Valve Stack Lifting Bracket

DFRW151—Radiator Cap Adapter

DFRW159—Auxiliary Drive Holding Bracket

DFRW173—Mid-Roller Mounting Bracket

John Deere Tracks Tractors 8120T, 8220T, 8320T, 8420T, 8520T Repair Service Manual (TM1971)