Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere 1023E, 1025R and 1026R Compact Utility Tractors, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere 1023E, 1025R and 1026R Compact Utility Tractor workshop technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm126919 - John Deere 1023E, 1025R and 1026R Compact Utility Tractor Technical Manual.pdf
tm126919 - John Deere 1023E, 1025R and 1026R Compact Utility Tractor Technical Manual.epub

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

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Handle Fuel Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service and Operate Chemical Sprayers Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Prevent Machine Runaway

Handle Starting Fluid Safely

Service Cooling System Safely

Stay Clear of Rotating Drivelines

Protect Against High Pressure Spray

Construct Dealer-Made Tools Safely

Clean Vehicle of Hazardous Pesticides

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Live With Safety

Group 10: General Specifications

Machine Specifications 1023E, 1025R, and 1026R EEC

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values—Grade 7

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Do Not Use Galvanized Containers

Lubricity of Diesel Fuel

Testing Diesel Fuel

BioDiesel Fuel

Filling Fuel Tank

Diesel Engine Break-In Oil

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Oil Filters

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

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

Testing Diesel Engine Coolant

Transmission and Hydraulic Oil

Use Correct Transmission/Hydraulic Filter Element

MFWD Axle Housing and Wheel Hub Oil

Grease

Grease (Specific Application)

Mixing of Lubricants

Alternative and Synthetic Lubricants

Lubricant Storage

Group 20: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Section 20: Engine Repair

Group 05: Engine

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Remove Engine—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Install Engine—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove Engine—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Install Engine—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Valve Cover

Remove and Install Rocker Arm Assembly and Push Rods

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

Remove and Install Exhaust Manifold

Remove and Install Cylinder Head

Disassemble and Assemble Cylinder Head

Recondition Cylinder Head

Replace Crankshaft Rear Oil Seal: 3TNM74

Replace Crankshaft Rear Oil Seal: 3TNV76 and 3TNV80

Remove and Install Crankshaft Rear Oil Seal Case: 3TNV76 and 3TNV80

Replace Crankshaft Front Oil Seal

Remove and Install Timing Gear Cover

Remove, Inspect, and Install Idler Gear

Remove, Inspect, and Install Camshaft Followers

Remove and Install Camshaft

Inspect Camshaft, Gear, Bushing and Bores

Remove and Install Oil Pan and Strainer: 3TNM74

Remove and Install Oil Pan and Strainer: 3TNV76 and 3TNV80

Check Connecting Rod Side Play

Check Crankshaft End Play

Check Connecting Rod Bearing Clearance

Check Crankshaft Main Bearing Clearance

Remove Piston and Connecting Rod

Install Piston and Connecting Rod

Disassemble and Inspect Piston and Connecting Rod

Assemble Piston and Connecting Rod

Inspect Cylinder Bore

Rebore Cylinder

Remove Crankshaft and Main Bearings: 3TNM74

Install Crankshaft and Main Bearings: 3TNM74

Remove Crankshaft and Main Bearings: 3TNV76 and 3TNV80

Install Crankshaft and Main Bearings: 3TNV76 and 3TNV80

Remove and Install Flywheel

Remove and Install Engine Back Plate

Inspect Oil Pump: 3TNM74

Inspect Oil Pump: 3TNV76 and 3TNV80

Group 10: Cooling System

Specifications

Remove and Install Fan and Alternator Belt

Remove and Install Radiator—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove and Install Radiator—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Water Pump—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove and Install Water Pump—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Thermostat

Remove and Install Coolant Temperature Sensor

Install Block Heater: 3TNM74

Install Block Heater: 3TNV76 and 3TNV80

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Other Material

Service Equipment and Tools

Bleed Fuel System

Remove and Install Fuel Transfer Pump

Remove and Install Fuel Injection Nozzle

Clean and Inspect Fuel Injection Nozzle

Remove Fuel Injection Pump: 3TNM74

Install Fuel Injection Pump: 3TNM74

Remove Fuel Injection Pump: 3TNV76 and 3TNV80

Install Fuel Injection Pump: 3TNV76 and 3TNV80

Remove and Install Fuel Shutoff Solenoid

Remove and Install Fuel Filter Assembly

Disassemble and Assemble Fuel Filter and Water Separator

Remove and Install Inline Fuel Filter

Group 10: Air Intake and Exhaust Systems

Remove and Install Muffler—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove and Install Muffler—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Group 15: Speed Control Linkage

Replace Throttle Cable—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Replace Throttle Cable—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Specifications

Essential or Recommended Tools

Remove and Install Battery

Remove and Install Starting Motor

Remove and Install Alternator

Disassemble and Inspect Alternator

Assemble Alternator

Group 15: Wiring Harness

Main Wiring Harness—1023E (S.N. —512600)

Main Wiring Harness—1025R (S.N. —324500)

Main Wiring Harness—1026R (S.N. —510500)

Main Wiring Harness—1023E (S.N. 512601— ) and 1025R (S.N. 324501— )

Main Wiring Harness—1026R (S.N. 510501— )

Fender Wiring Harness

Section 50: Power Train Repair

Group 15: Transmission

Specifications

Other Material

Remove Transmission—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Install Transmission—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove Transmission—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Install Transmission—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Hydrostatic Drive

Disassemble and Inspect Hydrostatic Drive

Assemble Hydrostatic Drive

Remove and Install Range Transmission

Group 20: Rear PTO Driveshaft

Specifications

Other Material

Essential or Recommended Tools

Remove PTO Clutch

Disassemble and Inspect PTO Clutch

Assemble PTO Clutch

Install PTO Clutch

Remove and Inspect Rear PTO Driveshaft and Gears

Install Rear PTO Driveshaft and Gears

Remove and Inspect Mid PTO Driveshaft and Gears

Install Mid PTO Driveshaft and Gears

Group 25: Differential

Specifications

Other Material

Remove and Install Differential

Disassemble and Inspect Differential

Assemble Differential

Group 30: Final Drives

Essential or Recommended Tools

Remove and Install Rear Axle

Group 35: Mechanical Front Wheel Drive

Specifications

Remove Front Axle

Install Front Axle

Disassemble Front Axle

Assemble Front Axle

Disassemble Front Outer Axle

Assemble Front Outer Axle

Disassemble MFWD Differential

Assemble MFWD Differential

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Specifications

Remove and Install Steering Wheel

Remove and Install Steering Cylinder

Remove and Install Tilt Steering Assembly—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove and Install Tilt Steering Assembly—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Disassemble Tilt Steering Assembly—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Assemble Tilt Steering Assembly—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Disassemble Tilt Steering Assembly—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Assemble Tilt Steering Assembly—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove Steering Control Unit (SCU)—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Install Steering Control Unit (SCU)—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove Steering Control Unit (SCU)—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Install Steering Control Unit (SCU)—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Tie Rod

Group 10: Brake Repair

Specifications

Other Material

Disassemble and Inspect Brakes

Assemble Brakes

Section 70: Hydraulics Repair

Group 05: Hydraulic Pump and Filter

Specifications

Remove and Install Hydraulic Pump

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Remove and Install Oil Suction Screen

Remove PTO Valve

Install PTO Valve

Group 10: Rockshaft

Specifications

Other Material

Remove Rockshaft Housing

Install Rockshaft Housing

Disassemble Rockshaft

Assemble Rockshaft

1025R Disassemble Rockshaft Position Feedback

1025R Assemble Rockshaft Position Feedback

Group 15: Selective Control Valve

Specifications

Remove and Install Selective Control Valve (SCV)

Inspect Selective Control Valve (SCV)

Section 80: Miscellaneous Repair

Group 10: Wheels

Specifications

Remove and Install Front Wheels

Remove and Install Rear Wheels

Group 15: 3-Point Hitch

Adjust 3-Point Hitch

Remove and Install 3-Point Hitch

Group 20: Hood

Remove and Install Hood—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove and Install Hood—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Group 25: Mid-Mount Lift

Specifications

Remove Mid Mount Mower Draft Arm

Install Mid Mount Mower Draft Arm

Remove Mid Mount Rockshaft and Lift Arm

Install Mid Mount Rockshaft and Lift Arm

Install Mid Mount Lift Actuator, Mechanical

Install Mid Mount Lift Actuator, Hydraulic

Remove Mid Mount Mower Lift Hydraulic Hose and Cylinder

Install Mid Mount Mower Lift Hydraulic Cylinder and Hose

Adjust Mid Mount Lift - Mechanical Lift

Section 90: Operator's Station Repair

Group 05: Seat and Support

Specifications

Remove Seat

Install Seat

Remove Seat Base

Install Seat Base

Group 10: ROLL-GARD

Specifications

Remove ROPS

Install ROPS

Group 15: Operator Platform

Specifications

Remove Control Panel—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Install Control Panel—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Remove Control Panel—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Install Control Panel—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Remove and Install Center Closeout Panel

Remove and Install Foot Deck—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Group 20: Fenders

Remove Right Fender

Install Right Fender

Remove Left Fender and Fuel Tank

Install Left Fender and Fuel Tank

Section 210: Operational Checkout Procedures

Group 05: Operational Checkout Procedures

Summary of References

System Checks

Rear Differential Lock Operational Check

PTO Operational Checks

RIO Operational Check

PTO and Seat Switch Interface Check

Brakes Operational Check

Steering Preliminary Check

Steering Operational Check

Hydraulic System Operational Checks

Section 220: Engine Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

3TNM74 Engine Component Locations

3TNV76 and 3TNV80 Engine Component Locations

Group 10: Theory of Operation

Summary of References

Cooling System Theory of Operation

Lubrication System Theory of Operation

Group 15: Diagnosis, Tests, and Adjustments

Summary of References

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Adjust Throttle Cable

Adjust Slow Idle

Adjust Fast Idle

Adjust Valve Clearance

Check Camshaft End Play

Check Timing Gear Backlash

Cylinder Compression Test—3TNM74

Cylinder Compression Test—3TNV76 and 3TNV80

Pressure Test Cooling System

Test Thermostat

Pressure Test Radiator Cap

Test Oil Pressure

Adjust Fan and Alternator Belt

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

Group 05: Component Location

Summary of References

Fuel System

Group 10: Theory of Operation

Summary of References

Air Intake System Theory of Operation

Fuel System Theory of Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Other Material

Service Equipment and Tools

Essential or Recommended Tools

Test Fuel Injection System

Test Fuel Injection Nozzle

Injection Pump Timing (EPA Engines)

Check Injection Pump Static Timing

Adjust Fuel Injection Timing: 3TNM74

Adjust Fuel Injection Timing: 3TNV76 and 3TNV80

Test Fuel Supply Pressure and Flow

Test Air Filter Restriction Indicator

Section 240: Electrical System Operation, Tests, and Adjustments

Group 05: Theory of Operation

Summary of References

Charging Circuit Theory of Operation

Cranking and Starting Circuit Theory of Operation

Instrument Control Cluster (ICC) Theory of Operation

Power Circuit Theory of Operation

PTO Circuit Theory of Operation

Lighting Circuit Theory of Operation

Group 10: Wiring Schematics

Wiring Schematics - Summary of References

Schematic Information

(SE01) Operator Station, Key Switch, Starting, and Charging

(SE02A) Lighting, Turn Signal, and Work Lights—1023E and 1025R

(SE02B) Lighting, Turn Signal and Horn—1026R

(SE03 - SE06) Instrument Control Cluster, Seat, Brake, Park Brake, Neutral Switches PTO, Power Port, and Mower

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Service Equipment and Tools

Essential or Recommended Tools

Power Circuit Diagnosis

Charge Circuit Diagnosis

Crank Circuit Diagnosis

Fuel Shutoff Circuit Diagnosis

Glow Plug Circuit Diagnosis

PTO Circuit Diagnosis

Lighting Circuit Diagnosis—1023E

Lighting Circuit Diagnosis—1025R

Instrument Control Cluster (ICC) Diagnosis

Key Switch Test

PTO Switch Test

Park Brake Switch Test

Reverse Pedal Switch Test

Reverse Pedal Switch Adjustment

Seat Switch Test

Light Switch Test

Turn Signal Switch Test

Hazard Switch Test

PTO MBR Switch Test

PTO Solenoid Test

Neutral Switch Test

Horn Switch Test

Relay Test

Oil Pressure Switch Test

Coolant Temperature Sensor Test

Fuel Shutoff Solenoid Test

Regulated Voltage Output Test

Group 20: Connector Information

Summary of References

E01 and E02 Headlight Connector

G02 Alternator Connector

J1 Display Connector—ICC

J2 Display Connector—ICC

J3 Display Connector—ICC

K01—K04 Relay Connector

K05—K06 Relay Connector

M01 Start Motor Connector

M02 Fuel Pump Connector

R01 Glow Plug Connector

S01 Key Switch Connector

S02 Light Switch Connector

S03 Turn Signal Switch Connector

S04 Neutral Start Switch Connector

S05 PTO Switch Connector

S08 MBR Switch Connector

S10 Mow Lift Switch Connector

S13 Hazard Switch Connector

S38 Seat Switch Connector

S40 Front Hitch Detection Connector

S41 Park Brake Switch Connector

S42 Brake Switch Connector

S60 Reverse Pedal Sense Connector

X03 Power Port Connector

X09 Mow Lift Solenoid Connector

X54 RH Fender Light Connector

X55 LH Fender Light Connector

Y02 Fuel Shutoff Solenoid Connector

Y03 PTO Solenoid Connector

Group 25: Component Location

Summary of References

Electrical Components

Load Center

Section 250: Power Train Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Transmission Sub-Assemblies

Driveshaft

Hydraulic Transmission

Gear Transmission Sub-Assemblies

Transmission Housing

Range Gears, Pinion, and Bevel Gear

Differential

Brakes

Axles

Mechanical Front Wheel Drive (MFWD)

PTO Clutch

PTO Drive

Rockshaft - 1023E

Rockshaft With Feedback - 1025R

Hydraulic Pump and PTO Valve

Front Axle Input Gear and Differential

Front Axle Case and Tie Rod

Front Axle Final Drive Gears

Group 10: Theory of Operation

Summary of References

Gear Train Operation

Range Gear Operation

MFWD Operation

PTO Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Essential or Recommended Tools

MFWD Diagnosis

Adjust Neutral Creep

Adjust Differential Lock

Adjust Forward and Reverse Pedals

Cone Point and Backlash Setting

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

Group 05: Component Location

Summary of References

Steering Components

Tilt Steering Components—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Tilt Steering Components—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

Brake Components

Park Brake Components - Export

Group 10: Theory of Operation

Summary of References

Steering System Operation

Group 15: Diagnosis, Test and Adjustments

Summary of References

Specifications

Adjust Brakes

Adjust Park Brake Engagement

Adjust Park Brake Engagement EEC

Check Toe-in

Steering Pressure Check

Steering System Test

Section 270: Hydraulic System Operation, Tests, and Adjustments

Group 05: Component Location

Summary of References

Hydraulic Pump—1023E (S.N. —512600), 1025R (S.N. —324500), 1026R (S.N. —510500)

Hydraulic Pump—1023E (S.N. 512601— ), 1025R (S.N. 324501— ), 1026R (S.N. 510501— )

PTO Solenoid

Group 10: Theory of Operation

Summary of References

Surge Relief Valve Operation

Group 15: Diagnosis

Summary of References

Diagnostic Information

Preliminary Hydraulic System Inspection

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down

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

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

Remote Cylinder Does Not Extend or Retract

Remote Cylinder Settles Under Load

Remote Cylinder Operates Too Fast or Too Slow

Group 20: Hydraulic Tests

Summary of References

Specifications

Essential or Recommended Tools

Hydraulic Oil Warm-up Procedure

Test SCV Implement Relief Pressure

Test PTO Cluch Pressure

Test HST Charge Pressure

Check Rate of Drop/Stop Valve

Pump Flow Test (Tractors With SCV)

Main Relief Valve Test (Tractors With SCV)

SCV Leakage Test

Rockshaft Lift Cycle Test

Rockshaft Leakdown Test

Group 25: Adjustments

Summary of References

Specifications

Adjust Rockshaft Position Feedback

Adjust Rockshaft Feedback Friction Washers

Group 30: Hydraulic Schematics

Summary of References

Hydraulic Circuit Symbols

1023E Hydraulic Schematic

1025R Hydraulic Schematic

Section 299: Service Tools

Group 05: Dealer Fabricated Tools

Summary of References

PTO Clutch Spring Compression Tool

Group 10: Service Tools and Kits

Essential or Recommended Tools

John Deere 1023E, 1025R and 1026R Compact Utility Tractor Diagnosis and Repair Service Manual (TM126919)