Complete Repair Service Technical Manual for John Deere 4WD Articulated Tractors 9100, 9200, 9300, 9400, 9120, 9220, 9320, 9420, 9520 and 9620, with all the technical information to maintain, repair, rebuild like professional mechanics.

John Deere 4WD Articulated Tractors 9100, 9200, 9300, 9400, 9120, 9220, 9320, 9420, 9520 and 9620 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.

tm1623 - John Deere Tractors 9100, 9200, 9300, 9400, 9120, 9220, 9320, 9420, 9520 and 9620 Repair Technical Manual.pdf

Total Pages: 1,808 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Notice to the Dealer
   Dealer Predelivery Information Form
   General Information
      Safety
      General Information
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel, Air, and Cooling Systems
      Diesel Fuel System
      Air Intake and Exhaust Systems
      Engine Cooling System
      Oil Coolers
   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
   18-Speed Power Shift Transmission (9020)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Transmission Cleanup
      Clutch Control
   12-Speed Power Shift Transmission (9000)
      Component Removal and Installation
      Clutch Control
      Transmission Oil Filter Relief Valve Housing and Oil Pump
      Transmission Pressure Regulating Valve
      On-Off and Modulating Shift Solenoids
      8-Inch Clutch Assembly
      Lower 7-Inch Clutch Assembly
      Upper 7-Inch Clutch Assembly
      Compound Shaft Assembly
      9-Inch Clutch Assembly
      Front and Rear Housings
      Transmission Cleanup
   Mechanical Shift Transmission (MST)
      Component Removal and Installation
      Transmission Oil Filter Relief Valve Housing
      Transmission Control Valve Housing
      Transmission Pump
      Transmission Front Cover
      Hi-Lo Clutch and Brake (24-Speed)
      Hi-Lo Planetary (24-Speed)
      Spacer Housing (24-Speed)
      Traction Clutch
      Transmission Gear Drives
      Transmission Cleanup
      Shift Levers and Linkage
   Drive Systems
      Component Removal and Installation
      Engine Coupler
      Drive Shafts
      PTO Clutch
      PTO Clutch Valve and Linkage
      PTO Drop Box
   Axles
      Component Removal and Installation
      Park Brake
      Repair Preparation
      Input Housing
      Differential
      Final Drives
      Brakes
   Steering and Brakes
      Steering Column
      Steering Control Valve
      Steering Cylinders
      Brake Valve
      Park Brake
   Hydraulics
      Component Removal and Installation
      Hydraulic System Repair
      Hydraulic Pump
      Axle Lubrication and Charge Pumps
      Filter Housings and Control Valves
      Hitch Valve, Selective Control Valves, and Couplers-9000 Series
      Hitch Valve, Selective Control Valves, and Couplers-9020 Series
      High-Flow Selective Control Valve-Scraper
      Hitch
   Miscellaneous
      Hood and Side Panels
      Heavy-Duty Wheels-9020 Tractors
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Air Suspension Seat (S.N. -030000)
      Air Suspension Seat (S.N. 030001- ) and 9020 Series
      ACTIVE SEAT™
      Armrest
      Cab Door and Windshield
   Hinge and Gudgeon
      Hinge
      Gudgeon
   Dealer Fabricated Tools
      Fabricated Tools

tm1623 - 9100, 92009300, 94009120, 92209320, 94209520 and 9620TractorsRepair

Table of Contents

Foreword

Notice to the Dealer

Dealer Predelivery Information Form

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Follow Safety Instructions

Practice Safe Maintenance

Protect Against High Pressure Spray

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Agricultural Chemicals 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

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

Live With Safety

Service Tires Safely

Protect Against Noise

Keep ROPS Installed Properly

Service Accumulator Systems Safely

Wait Before Opening High-Pressure Fuel System

Group 10: General Information

General Specifications—9000 Series

General Specifications—9020 Series

General Specifications—9000 and 9020 Series

Identify Zinc-Flake Coated Fasteners

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Sealants and Adhesives Cross-Reference Chart

Glossary of Terms

Section 20: Engine

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Remove 8.1 L Engine—9000 Series

Remove 8.1 L Engine—9020 Series

Install 8.1 L Engine

Engine Identification—10.5 L and 12.5 L Engines

Remove 10.5 L and 12.5 L Engine—Dual-Rail

Remove 10.5 L and 12.5 L Engine—Single-Rail

Install 10.5 L and 12.5 L Engine

Determine Engine Shim Pack

Group 05: Engine Repair

Repair Engine—Use CTM

Other Material

Specifications

Remove and Install Oil Pan—8.1 L Engine

Section 30: Fuel, Air, and Cooling Systems

Group 05: Diesel Fuel System

Remove and Install Left Fuel Tank

Remove, and Install Right Fuel Tank

Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Group 10: Air Intake and Exhaust Systems

Specifications

Install Muffler

Air Intake Pipe Connections

Turbocharger Inlet Hose

Air Intake Pipe Installation

Inspect Air Intake System

Service Air Intake System

Group 15: Engine Cooling System

Essential or Recommended Tools

Specifications

Test Radiator and Coolant Tank

Test Radiator Cap

Remove and Install Radiator

Remove and Install Aftercooler

Remove and Install Viscous Fan Drive

Inspect Belt Tensioner

Drive Belt Routings

Group 20: Oil Coolers

Essential or Recommended Tools

Specifications

Remove and Install Oil Cooler—9100, 9200

Remove and Install Axle Oil Cooler—9300, 9400

Remove and Install Hydraulic/Transmission Oil Cooler—9300, 9400

Remove and Install Oil Cooler—9020 Series

Leak Test Oil Coolers

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 32 and 48 Way 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 DEUTSCH™ Implement 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 Numbers and Color Codes

Engine Identification—10.5 L and 12.5 L Engines

Ground Point Locations

Chassis Single Point Grounds

Cab Ground (Roof)

Cab Ground (Floor)

# 4 Cab-To-Chassis Ground Cable

Miscellaneous Grounds

Engine/Chassis Harness Routing and Component Identification—9100 MST

Engine/Chassis Harness Routing and Component Identification—9.0 L

Dual-Rail Engine/Chassis Harness Routing and Component Identification—9200, 9300, and 9400 MST

Single-Rail Engine/Chassis Harness Routing and Component Identification—9200, 9300, and 9400 MST

Engine/Chassis Harness Routing and Component Identification—9220, 9320, 9420, and 9520 MST

Rear Engine/Chassis Harness Routing and Component Identification—MST

Engine/Chassis Harness Routing and Component Identification—9120 PST

Dual-Rail Engine/Chassis Harness Routing and Component Identification—9000 PST

Single-Rail Engine/Chassis Harness Routing and Component Identification—9000 PST

Engine/Chassis Harness Routing and Component Identification—13.5 L (North American)

Rear Engine/Chassis Harness Routing and Component Identification—PST

Engine/Chassis Harness Routing and Component Identification—13.5 L (European)

Rear European Engine/Chassis Harness Routing and Component Identification—PST

Transmission Harness Routing and Component Identification—PST

Transmission Harness Routing and Component Identification—9020 Series w/PST (S.N. —011407)

Cab Harness Routing and Component Identification—9100—9400 (S.N. —30000) MST

Cab Harness Routing and Component Identification—9100—9400 (S.N. 30001— ) MST

Cab Harness Routing and Component Identification—9100—9400 (S.N. —30000) PST

Cab Harness Routing and Component Identification—9100—9400 (S.N. 30001— ) PST

Cab Harness Routing and Component Identification—PST

Cab Harness Routing and Component Identification—European

Roof Harness Routing and Component Identification—North American

Roof Harness Routing and Component Identification—European

ACTIVE SEAT ACTIVE SEAT is a trademark of Deere & Company 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

Group 15: Charging Circuit

Disconnect Electrical Circuit

Repair Alternator—Use CTM

Exploded View—Alternator

Replace Alternator

Alternator Power Cable Routing

Replace Batteries

Group 20: Starting Circuit

Essential or Recommended Tools

Specifications

Repair Starter—Use CTM77

Disconnect Electrical Circuit

Remove and Install Starter

Replace Fusible Link

Remove and Install Start Circuit Relay

Group 25: Relays, Fuses, Solenoids, and Switches

Specifications

General Repair Procedures—Solenoids

Disconnect Electrical Circuit

Load Center Fuses—9000 Series

Load Center Fuses—9020 Series (S.N. —009999)

Load Center Fuses

Load Center Relays and Diodes—9000 Series

Load Center Relays and Diodes—9020 Series (S.N. —009999)

Load Center Relays and Diodes

Replace Starting Aid Solenoid

Replace Fuel Shut-Off Solenoid

Replace Differential Lock Solenoid

Replace Two-Speed Clutch Hi-Lo Solenoid—MST

Replace Solenoid Valves—PST

Replace Park Brake Valve Solenoids

Replace Park Brake Valve Solenoids—9020 Series w/PST (S.N. —011407)

Replace SCV Solenoids

Replace Hitch Valve Solenoids

Exploded View—Right Console Controls and Switches—9000

Exploded View—Right Console Controls and Switches

Replace Right Console Switches

Replace Engine Oil Pressure Switch

Replace Starting Aid and Ignition Switch

Replace Clutch On/Off Switch

Replace Clutch Up and Down Switch Assembly

Replace Differential Lock Switch

Neutral Start Switch—MST

Replace Neutral Start Switch—PST

Replace Rear PTO Switch

Replace Brake Switch

Replace Dome Light Switch

Replace Cab Door Light Switch

Replace Beacon Light Switch

Replace Seat Raise/Lower Switch

Replace Operator Presence Seat Switch

Replace Hand Brake Switch—9000 PST European

Replace Hand Brake Switch and Potentiometer (European)

Replace Park Brake Valve Pressure Sensor

Replace Park Brake Valve Pressure Switch—9020 Series w/PST (S.N. —011407)

Replace External Hitch Raise/Lower Switch

Replace A/C High- and Low-Pressure Switches

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 and Gauges 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

Replace Control Units—9000 Series

Replace Control Units

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

Remove EEPROM

Replace Power Shift Controller—9000 PST

Replace Engine Cam Speed Sensor

Replace Engine Crank Speed Sensor—9000 Series

Replace Engine Crank Speed Sensor

Replace Engine Coolant Temperature Sensors

Replace Fuel Level Sensor

Replace Fuel Temperature Sensor

Replace Air Filter Restriction Sensor

Replace Manifold Air Intake Temperature Sensor (MAT)

Remove, Inspect, and Adjust Clutch Position Sensor

Replace Transmission Input and Output Speed Sensor—9000 PST

Replace Transmission Oil Temperature Sensor—9000 PST

Replace Transmission Filter Restriction Sensor—9000 PST

Replace Transmission Lube Oil Pressure Sensor—9000 PST

Replace Transmission Lube Oil Pressure Sensor—MST

Replace Transmission Oil Filter Restriction Sensor—MST

Replace Axle Lube Filter Restriction Sensor—9000 PST

Replace Axle Lube Pressure Sensor—9000 PST

Replace Axle Lube Pressure Sensor

Replace Axle Lube Pressure Sensor—MST

Replace Hydraulic Oil Temperature Sensor

Replace Hydraulic Oil Reservoir Level Sensor

Replace Hydraulic Oil Filter Restriction Sensor

Replace Wheel Speed Sensor—MST

Replace Radar Sensor

Replace Hitch Position Sensor

Remove, Install, and Adjust Draft 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

Replace Proximity Sensor

Replace Front Driveshaft Health Control Unit

Group 35: Armrest Control

Armrest Test Procedures

Exploded View—Armrest Control—9000 Series

Exploded View—Armrest Control

Replace Armrest Control Assembly

Replace Armrest Control Unit (ACU)

Replace Armrest Controls—9000 Series

Replace Armrest Controls

Exploded View—Engine Speed Control

Exploded View—Transmission Control (PST)

Exploded View—Hi-Lo Clutch Control (MST)

Replace Hitch Control

Exploded View—SCV Control Lever

Group 40: Implement and Accessory Connectors

Replace Seven-Terminal Outlet Socket

TOUCHSET™ Depth Control Connector

Diagnostic/Program

ECU Diagnostic Connector

Group 45: Convenience and Accessory Components

Replace Circulation Blower Motor

Replace Pressurizer Blower Motor

Replace Wiper Motors

Replace Windshield Washer Pumps

Remove Radio and Speakers—Style A

Remove Radio and Speaker

Section 50: 18-Speed Power Shift Transmission (9020)

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Power Shift Transmission

Install Transmission to Rollover Stand Bracket

Install Power Shift Transmission

Check Transmission Oil Level

Group 05: In Tractor Repair

Essential or Recommended Tools

Other Material

Specifications

Remove Filter Relief Valve

Disassemble and Assemble Filter Relief Valve

Remove, Repair, and Install Filter Relief Valve Housing

Remove and Install Input and Output Yokes

Repair Internal Park Brake (S.N. 011408— )

Replace Input and Output Shaft Seals

Group 10: Transmission Repair

Repair 18-Speed PST

Group 15: Transmission Cleanup

Essential or Recommended Tools

Perform Transmission Cleanup

Group 20: Clutch Control

Repair Clutch Pedal Assembly

Section 52: 12-Speed Power Shift Transmission (9000)

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Power Shift Transmission

Install Transmission on Engine Rotation Stand

Install Power Shift Transmission

Shim Transmission

Check Transmission Oil Level

Group 05: Clutch Control

Repair Clutch Pedal

Group 10: Transmission Oil Filter Relief Valve Housing and Oil Pump

Essential or Recommended Tools

Specifications

Remove and Install Transmission Filter Relief Valve Housing

Disassemble and Assemble Filter Relief Valve Housing

Repair Oil Distribution Manifold

Remove, Inspect, and Install Oil Pump

Group 15: Transmission Pressure Regulating Valve

Essential or Recommended Tools

Specifications

Remove, Inspect, and Install Pressure Regulating Valve

Group 20: On-Off and Modulating Shift Solenoids

Essential or Recommended Tools

Specifications

Replace Solenoids

Remove and Replace Modulating Shift Valves

Clean and Inspect Modulating Shift Valves

Remove and Replace On-Off Shift Valve Solenoids

Group 25: 8-Inch Clutch Assembly

Essential or Recommended Tools

Specifications

Cross-Sectional View—8-Inch Clutch Assembly

Exploded View—8-Inch Clutch Assembly

Disassemble and Inspect 8-Inch Clutch

Assemble 8-Inch Clutch

Group 30: Lower 7-Inch Clutch Assembly

Essential or Recommended Tools

Specifications

Cross-Sectional View—Lower 7-Inch Clutch Assembly

Exploded View—Lower 7-Inch Clutch Assembly

Disassemble and Inspect Lower 7-Inch Clutch

Assemble Lower 7-Inch Clutch

Group 35: Upper 7-Inch Clutch Assembly

Essential or Recommended Tools

Specifications

Cross-Sectional View—Upper 7-Inch Clutch Assembly

Exploded View—Upper 7-Inch Clutch Assembly

Disassemble and Inspect Upper 7-Inch Clutch

Assemble Upper 7-Inch Clutch

Group 40: Compound Shaft Assembly

Essential or Recommended Tools

Cross-Sectional View—Compound Shaft Assembly

Exploded View—Compound Shaft Assembly

Disassemble Compound Shaft

Assemble Compound Shaft

Group 45: 9-Inch Clutch Assembly

Essential or Recommended Tools

Specifications

Cross-Sectional View—9-Inch Clutch Assembly

Exploded View—9-Inch Clutch Assembly

Disassemble and Inspect 9-Inch Clutch

Assemble 9-Inch Clutch

Group 50: Front and Rear Housings

Essential or Recommended Tools

Other Material

Specifications

Disassemble Transmission

Remove and Install All Shafts

Remove and Install Upper 7-Inch Clutch Shaft Assembly

Remove and Install Lower 7-Inch Clutch Shaft Assembly

Remove and Install Compound Shaft Assembly

Remove and Install 8-Inch Clutch Shaft Assembly

Remove and Install 9-Inch Clutch Shaft Assembly

Disassemble and Assemble Front and Rear Housings

Assemble Transmission

Adjust Clutch Shaft End Play

Adjust Upper 7-Inch Clutch Shaft End Play

Adjust Lower 7-Inch Clutch Shaft End Play

Adjust Compound Shaft End Play

Adjust 9-Inch Clutch Shaft End Play Adjustment

Adjust 8-Inch Clutch Shaft End Play

Replace Front Output Shaft Oil Seal

Replace Input Shaft Oil Seal

Install Input and Front Output Yokes

Install Rear Output Yoke

Adjust Speed Sensors

Group 55: Transmission Cleanup

Essential or Recommended Tools

Other Material

Perform Transmission Cleanup

Section 55: Mechanical Shift Transmission (MST)

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Mechanical Shift Transmission

Install Transmission on Engine Rotation Stand

Install Mechanical Shift Transmission

Shim Transmission—9000 Series

Transmission/Axle Oil Fill—All MST & 9020 PST

Check Transmission Oil Level

Group 05: Transmission Oil Filter Relief Valve Housing

Specifications

Remove Filter Relief Valve Housing

Install Filter Relief Valve Housing

Group 10: Transmission Control Valve Housing

Essential or Recommended Tools

Other Material

Specifications

Repair Clutch Pedal

Remove and Install Clutch Operating Cable

Adjust Clutch Cable

Remove Transmission Control Valve Housing

Cross-Sectional View—Transmission Control Valve

Exploded View—Transmission Control Valve

Disassemble, Inspect, and Assemble Transmission Control Valve Housing

Install Transmission Control Valve

Group 15: Transmission Pump

Specifications

Remove Transmission Pump

Cross-Sectional View—Transmission Pump and Bearing Quill (12-Speed)

Exploded View—Transmission Pump and Bearing Quill (12-Speed)

Cross-Sectional View—Transmission Pump and Bearing Quill (24-Speed)

Disassemble, Inspect, and Assemble Transmission Pump

Install Transmission Pump

Group 20: Transmission Front Cover

Essential or Recommended Tools

Other Material

Specifications

Remove Transmission Front Cover

Remove, Inspect, and Install Front Cover Parts

Install Transmission Front Cover

Group 25: Hi-Lo Clutch and Brake (24-Speed)

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—Hi-Lo Clutch and Brake

Exploded View—Hi-Lo Clutch and Brake

Remove Clutch and Brake Pack

Disassemble, Inspect, and Assemble Hi-Lo Clutch and Brake Assembly

Install Hi-Lo Clutch and Brake Assembly

Group 30: Hi-Lo Planetary (24-Speed)

Essential or Recommended Tools

Specifications

Cross-Sectional View—Hi-Lo Planetary

Exploded View—Hi-Lo Planetary

Remove Hi-Lo Planetary Assembly

Disassemble, Inspect, and Assemble Hi-Lo Planetary

Install Hi-Lo Planetary Assembly

Group 35: Spacer Housing (24-Speed)

Other Material

Remove, Inspect, and Install Spacer Housing and Parts

Group 40: Traction Clutch

Essential or Recommended Tools

Other Material

Specifications

Remove Traction Clutch Assembly

Cross-Sectional View—Traction Clutch

Exploded View—Traction Clutch

Disassemble, Inspect, and Assemble Traction Clutch

Remove and Inspect Traction Clutch Manifold

Install Traction Clutch Manifold

Install Traction Clutch Assembly

Group 45: Transmission Gear Drives

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—Transmission Gear Drives

Remove Transmission Top Shaft, Upper Countershaft, Lower Countershaft, and Output Shaft

Cross-Sectional and Exploded Views—Top Shaft

Cross-Sectional and Exploded Views—Upper Countershaft

Cross-Sectional and Exploded Views—Lower Countershaft

Cross-Sectional and Exploded Views—Output Shaft

Disassemble and Inspect Shafts

Disassemble, Inspect, and Assemble Drive/Shift Collar (12-Speed)

Disassemble and Inspect Synchronizer

Assemble Synchronizer

Assemble Lower Countershaft

Assemble Upper Countershaft

Disassemble and Assemble Park Pawl Assembly

Cross-Sectional and Exploded Views—Shifter Cams

Remove and Install Shifter Cams

Adjust Neutral Start and Reverse Switches

Disassemble and Assemble Shifter Fork

Remove and Install Front Case Parts

Remove and Install Reverse Idler Gear

Install Transmission Shafts

Install Rear Case

Adjust Shaft End Play

Install Yoke Seals and Yokes

Group 50: Transmission Cleanup

Essential or Recommended Tools

Other Material

Perform Transmission Cleanup

Group 55: Shift Levers and Linkage

Specifications

Remove and Install Shift Lever Control Assembly

Exploded View—Shifter Lever Control Assembly Components

Disassemble, Inspect, and Assemble Shift Lever Control Assembly

Remove, Disassemble, Assemble, and Install Upper Shift Rods

Remove, Disassemble, and Assemble Shifter Bell Crank Components

Install Bell Crank Assembly

Remove, Disassemble, Assemble, and Install Lower Shift Rods

Adjust Lower Shift Rods

Adjust Neutral Lockout Plate

Section 56: Drive Systems

Group 00: Component Removal and Installation

Essential or Recommended Tools

Specifications

Remove and Install PTO Clutch

PTO-to-Transmission Alignment

Remove and Install PTO Drop Box Assembly

Group 05: Engine Coupler

Other Material

Specifications

Replace Engine Coupler

Group 10: Drive Shafts

Specifications

Remove and Install Drive Shaft Retainer

Inspect and Replace Universal Joints

Group 15: PTO Clutch

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—PTO Clutch Assembly

Exploded View—PTO Rear Cover and Brake Assembly

Exploded View—PTO Clutch Housing and Shaft

Exploded View—PTO Clutch Assembly

Disassemble, Inspect, and Assemble PTO Clutch

Group 20: PTO Clutch Valve and Linkage

Other Material

Specifications

Remove and Install PTO Clutch Valve

Disassemble, Inspect, and Assemble PTO Clutch Valve

Remove and Install PTO Clutch Lever

Replace PTO Clutch Operating Cable

Adjust PTO Clutch Operating Cable

Group 25: PTO Drop Box

Essential or Recommended Tools

Other Material

Specifications

Cross-Sectional View—PTO Housing Assembly

Disassemble, Inspect, and Assemble PTO Drop Box

Section 57: Axles

Group 00: Component Removal and Installation

Essential, Recommended and Fabricated Tools

Specifications

Remove and Install Front Axle Assembly

Remove and Install Rear Axle Assembly

Check Axle Oil Level—9000 PST

Group 02: Park Brake

Specifications

Inspect Park Brake Disk

Group 03: Repair Preparation

Essential Tools

Specifications

Remove and Install Park Brake Components—9000 PST and European MST

Remove and Install Park Brake Components——9020 Series w/PST (S.N. —011407)

Install and Remove Axle Assembly in Repair Stand

Group 05: Input Housing

Essential or Recommended Tools

Other Material

Specifications

Replace Vent Tube

Remove Input Housing/Cover

Cross-Sectional View—Input Housing/Cover

Disassemble Input Housing/Cover

Assemble Input Housing/Cover

Determine Spiral Bevel Pinion Shaft Cone Point Shim Pack

Continue Assembly of Input Housing Cover

Adjust Differential Drive Shaft

Install Input Housing/Cover

Group 10: Differential

Essential or Recommended Tools

Other Material

Specifications

Remove Differential

Cross-Sectional View—Differential with Differential Lock

Cross-Sectional View—Standard Differential

Disassemble, Inspect, and Assemble Differential

Install Differential

Adjust Differential Preload

Adjust Differential Backlash

Group 15: Final Drives

Essential or Recommended Tools

Other Material

Specifications

Remove Final Drive Assemblies

Cross-Sectional View—Final Drive

Disassemble Final Drive

Disassemble, Inspect, and Assemble Planet Pinion Carrier

Remove Axle Housing

Disassemble and Assemble Axle Housing

Disassemble, Inspect, and Assemble Axle Shaft

Install Axle Housing

Adjust Axle Bearings

Install Final Drive Assemblies

Group 20: Brakes

Specifications

Replace Brakes

Section 60: Steering and Brakes

Group 05: Steering Column

Specifications

Repair Steering Column

Group 10: Steering Control Valve

Specifications

Remove and Install Steering Valve

Exploded View—Steering Control Valve

Disassemble, Inspect, and Assemble Steering Valve

Group 15: Steering Cylinders

Essential or Recommended Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Steering Cylinders

Disassemble and Assemble Steering Cylinder

Group 20: Brake Valve

Essential or Recommended Tools

Service Parts Kits

Specifications

General Repair Procedures—Brake Valve

Remove and Install Brake Valve

Disassemble, Inspect, and Assemble Brake Valve

Adjust Brake Pedal

Bleed Brakes

Check Manual Brakes

Group 25: Park Brake

Essential or Recommended Tools

Specifications

Manual Park Brake Release——9020 Series w/PST (S.N. —011407)

Manual Park Brake Release—9020 Series w/PST (S.N. 011408— )

Exploded View—Park Brake Caliper—9020 Series w/PST (S.N. —011407)

Exploded View—Park Brake Valve 9020 Series w/PST (S.N. —002423)

Exploded View—Park Brake Valve 9020 Series w/PST (S.N. 002424—011407)

Park Brake Valve Hose Connections—Park Brake Caliper—9020 Series w/PST (S.N. —011407)

Inspect Park Brake Disk (If Equipped)

Remove and Install Park Brake Caliper (If Equipped)

Exploded View—Park Brake Caliper—9020 Series w/PST (S.N. —011407)

Adjusting Park Brake—9000 Series w/PST (S.N. 030001—040000)

Park Brake Adjustment—9020 Series w/PST (S.N. —011407)

Secondary Brake Adjustment—9020 Series w/PST (S.N. 011408— )

Section 70: Hydraulics

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Hydraulic Oil Reservoir

Remove and Install Hydraulic Pump—9000 MST and 9020 Series

Remove and Install Hydraulic Pump—9000 PST

Remove and Install High-Flow Hydraulic Pumps

Fill Hydraulic Pump Crankcase

Group 05: Hydraulic System Repair

Essential or Recommended Tools

Specifications

Disconnect Battery Ground Cable

Use Special Wrench

Install Hydraulic Fittings

Drain and Fill Hydraulic Reservoir

Group 10: Hydraulic Pump

Essential or Recommended Tools

Service Parts Kits

Other Material

Specifications

Pump Identification—9000 Series

Pump Identification—High-Flow Hydraulic

Remove and Install Hydraulic Pump Controller—Vickers

Exploded View—Hydraulic Pump Controller—Vickers

Disassemble, Inspect, and Assemble Hydraulic Pump Controller—Vickers

Exploded View—Hydraulic Pump—Vickers

Disassemble and Inspect Hydraulic Pump—Vickers

Remove and Install Pump Shaft Seal—Vickers

Assemble Hydraulic Pump—Vickers

Exploded View—Hydraulic Pump—Sauer

Service Hydraulic Pump Control—Sauer

Disassemble and Inspect Hydraulic Pump—Sauer

Replace Hydraulic Pump Shaft Seal—Sauer

Assemble Hydraulic Pump—Sauer

Replace Shaft Seal—45 cm3 Pump

Service Hydraulic Pump Control—45 cm3 Pump

Repair Hydraulic Pump—45 cm3 Pump

Group 15: Axle Lubrication and Charge Pumps

Essential or Recommended Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Axle Lubrication Pump—9000 MST and 9020 Series

Exploded View—Axle Lubrication Pump—9000 MST and 9020 Series

Disassemble, Inspect, and Assemble Axle Lubrication Pump—9000 MST and 9020 Series

Remove and Install Axle Lubrication Pump—9000 PST

Exploded View—Axle Lubrication Pump—9000 PST

Disassemble, Inspect, and Assemble Axle Lubrication Pump—9000 PST

Remove and Install Charge Pump—9000 PST

Exploded View—Charge Pump—9000 PST

Disassemble, Inspect, and Assemble Charge Pump—9000 PST

Group 20: Filter Housings and Control Valves

Service Parts Kits

Specifications

Remove, Inspect, and Install Hydraulic Filter Housing

Remove, Inspect, and Install Axle Filter Housing—9000 PST

Repair Sequence Valve—9000 PST

Disassemble and Assemble Return Oil Manifold—9000 PST

Reference—Priority Valve

Remove and Install Priority Valve

Disassemble, Inspect, and Assemble Priority Valve

Remove and Install Differential Lock Valve

Exploded View—Differential Lock Valve

Inspect Differential Lock Valve

Remove, Inspect, and Install Cooler Bypass Valve—9000 Series and 9020 MST

Group 25: Hitch Valve, Selective Control Valves, and Couplers—9000 Series

Essential or Recommended Tools

Service Parts Kits

Specifications

Remove and Install Hitch-SCV Valve Stack

Disassemble and Assemble Hitch-SCV Valve Stack

Disassemble, Inspect, and Assemble Hitch Manifold

Remove, Inspect, and Install Hitch and SCV Solenoids

Disassemble, Inspect, and Assemble Hitch Valve

Test Surge Relief Valve

Disassemble, Inspect, and Assemble Selective Control Valve

Exploded View—Coupler

Repair SCV Couplers

Group 30: Hitch Valve, Selective Control Valves, and Couplers—9020 Series

Essential or Recommended Tools

Specifications

Remove and Install Hitch-SCV Valve Stack

Top Cover Identification

Exploded View—Standard End Cover

Exploded View—Deluxe End Cover

Disassemble and Assemble Hitch-SCV Valve Stack

Disassemble and Assemble High Flow SCV Valve Stack

Disassemble, Inspect, and Assemble Hitch Valve

Test High Pressure Relief Valve

Disassemble, Inspect, and Assemble Selective Control Valve

Repair SCV Couplers

Disassemble, Inspect, and Assemble Hitch Manifold

Group 35: High-Flow Selective Control Valve—Scraper

Specifications

Remove and Install High-Flow SCV Stack

Repair High-Flow SCV Stack

Group 40: Hitch

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Lift Cylinder

Cross-Sectional and Exploded View—90 mm Lift Cylinder

Cross-Sectional and Exploded View—100 mm Lift Cylinder

Disassemble, Inspect, and Assemble Lift Cylinder

Repair Hitch Lift Arm Assembly

Section 80: Miscellaneous

Group 05: Hood and Side Panels

Essential or Recommended Tools

Remove and Install Hood

Releasing Broken Hood Latch

Adjust Hood

Adjust Side Panel

Group 10: Heavy-Duty Wheels—9020 Tractors

Specifications

Service Heavy-Duty Wheel Clamps

Section 90: Operator Station

Group 00: Component Removal and Installation

Essential or Recommended Tools

Other Material

Specifications

Remove Cab

Exploded View—Cab Mounts

Install Cab

Repair Cab

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

Specifications

Heater Line Routing

Remove HVAC Module

Install HVAC Module

Remove and Install Temperature Control Cable

Adjust Heating/Cooling Controls

Remove and Install Heater Core

Leak Test Heater Core

Remove, Test, 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 (S.N. —010001):

Remove and Install Heater Control Valve With CLIMATRAK CLIMATRAK is a trademark of Deere & Company ( S.N 010001- )

Group 10: Air Conditioning System

Essential or Recommended Tools

Other Material

Service Parts Kits

Specifications

Hose and Tubing O-Ring Connection Torques

Diagram—Air Conditioning System

Reference Chart—Air Conditioning System Fittings

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 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

Inspect Compressor Thermal Bypass Valve

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

Replace Receiver-Dryer

Leak Test Condenser

Remove Air Conditioning Condenser

Leak Test Evaporator

Remove and Install Evaporator

Remove and InstallExpansion Valve

Group 15: Air Suspension Seat (S.N. —030000)

Other Material

Remove Seat and Swivel Plate From Suspension

Disassemble, Inspect, and Assemble Air Suspension Assembly

Group 20: Air Suspension Seat (S.N. 030001— ) and 9020 Series

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Seat

Repair Air System

Remove and Install Ride Zone Protector (RZP)—9000 Series

Repair Suspension

Repair Seat Back

Repair Control Knobs

Group 25: ACTIVE SEAT™

Essential or Recommended 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 ACTIVE SEAT is a trademark of Deere & Company Actuator

Remove and Install Actuator Hoses

Remove and Install Seat Control Valve Assembly

Exploded View—ACTIVE SEAT™ Hydraulic Control Valve Block

Replace Seat Control Valve Assembly O-Rings

Remove and Install Accumulator

Checking and Charging Replacement Accumulators

Repair Active Seat Air System

Repair Active Seat Suspension

Repair Seat Back

Group 30: Armrest

Remove and Install Armrest Control

Disassemble and Assemble Armrest Adjustment Assembly—Style A

Disassemble and Assemble Adjustable Armrest Support—Style B

Group 35: Cab Door and Windshield

Door Latch Identification—Version "A" and Version "B"

Repair Cab Door Latch

Cab Door Adjustment

Replace Windshield Glass or Seal

Section 95: Hinge and Gudgeon

Group 05: Hinge

Essential or Recommended Tools

Other Material

Specifications

Replace Hinge Pins and Bushings

Group 10: Gudgeon

Essential or Recommended Tools

Other Material

Specifications

Remove Gudgeon Drive Shaft

Inspect Universal Joint and Drive Shaft

Install Gudgeon Drive Shaft

Replace Gudgeon Journal Bearings, Thrust Bearings, and Wear Plates—Standard Duty Gudgeon

Replace Gudgeon Journal Bearings, Thrust Bearings, and Wear Plates—Severe Duty Gudgeon

Replace Gudgeon Spindle

Section 99: Dealer Fabricated Tools

Group 05: Fabricated Tools

Fabricated Tools

DF1057—Axle Adjusting Tool

DFRW7—Differential Lifting Tool

DFRW13—PST Clutch Clip

DFRW20—Compressor Holding Fixture

DFRW30A—Axle Jacking Tool

DRFW60 - DFRW61 - DFRW62—Extension Harnesses

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

DFRW72—Gudgeon Spindle Cooling Box

DFRW92—Mounting Guide Pins

DFRW94—Rear Axle Support Stand

DFRW103—Yoke Holding Tool Tool may be purchased. Order JDG924

DFRW113—Hood Supports Tool may be purchased. Order JDG1007

DFRW116—Hydraulic Reservoir Siphon Tube

DFRW117—Transmission-Hydraulic Flusher

DFRW139—Thermal Expansion Valve Replacement Tool

DFRW147—Screw Jack

DFRW148—ACTIVE SEAT ACTIVE SEAT is a trademark of Deere & Company Control Valve Holding Tool

DFRW150—SCV-Hitch Valve Stack Lifting Bracket

DFRW155—Jumper Leads

DFRW165—PST Park Brake Pump Off Hose Adapter

DFRW169—Gudgeon Oscillation Stop This tool may be purchased. Order JDG660B.

DFRW198—Accumulator Service Tool

John Deere Tractors 9100, 9200, 9300, 9400, 9120, 9220, 9320, 9420, 9520, 9620 Repair Service Manual (TM1623)