John Deere 2020A-2030A Progators Technical Manual TM2374
INTRODUCTION
Manual Description
This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows:
•Table of Contents
•Specifications and Information
•Identification Numbers
•Tools and Materials
•Component Location
•Schematics and Harnesses
•Theory of Operation
•Operation and Diagnostics
•Diagnostics
•Tests and Adjustments
•Repair
•Other
NOTE: Depending on the particular section or system being covered, not all of the above groups may be used.
The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section.
We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.
All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.
This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe servicing practices.
Understand Signal Words
A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
Replace Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
MIF
MIF
MIF
SAFETY
Use Care in Handling and Servicing Batteries
Use Care Around High-Pressure Fluid Lines
Avoid
High-Pressure Fluids
Prevent Battery Explosions
•Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
•Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
•Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prevent Acid Burns
•Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid acid burns by:
1.Filling batteries in a well-ventilated area.
2.Wearing eye protection and rubber gloves.
3.Avoiding breathing fumes when electrolyte is added.
4.Avoiding spilling or dripping electrolyte.
5.Use proper jump start procedure.
If you spill acid on yourself:
1.Flush your skin with water.
2.Apply baking soda or lime to help neutralize the acid.
3.Flush your eyes with water for 10-15 minutes.
4.Get medical attention immediately.
If acid is swallowed:
1.Drink large amounts of water or milk.
2.Then drink milk of magnesia, beaten eggs, or vegetable oil.
3.Get medical attention immediately.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
SPECIFICATIONS AND INFORMATION PRODUCT IDENTIFICATION
Product Identification
Identification Numbers
When ordering parts or submitting a warranty claim, it is IMPORTANT that you include the product identification number, and the component product identification numbers.
The location of the product identification numbers and component product identification numbers are shown.
Backlash for All Timing Gears (Except Crankshaft Gear-to-Oil Pump Gear)
Oil Pump Gear Backlash (Max).
Camshaft End Play.
Camshaft End Play (Max).
Camshaft Bend.
Camshaft Bend (Max).
Camshaft Lobe Height.
Camshaft Lobe Height Wear Limit
Camshaft Bearing Journals
Timing Gear End Journal OD
Timing Gear End Journal OD Wear Limit.
Flywheel End Journal OD Wear Limit.
Camshaft Bushing ID.
Camshaft Bushing ID Wear Limit
Camshaft Bushing ID Oil Clearance.
Camshaft Intermediate Bore ID.
Camshaft Intermediate Bore ID Wear Limit
Camshaft Intermediate Bore ID Oil Clearance.
Camshaft Flywheel End Bore ID.
Camshaft Flywheel End Bore ID Wear Limit .
Camshaft Flywheel End Bore ID Oil Clearance.
Crankshaft
Crankshaft Connecting Rod Journal OD
Crankshaft Connecting Rod Journal OD Wear Limit
Crankshaft Main Bearing Journal OD.
Crankshaft Main Bearing Journal OD Wear Limit
Main Bearing ID
Main Bearing ID Wear Limit.
Crankshaft Main Bearing Oil Clearance.
Crankshaft Main Bearing Oil Clearance Wear Limit
Connecting Rod Bearing Oil Clearance.
Connecting Rod Bearing Oil Clearance Wear Limit
Connecting Rod Side Play (Max)
Connecting Rod
Crankshaft Connecting Rod Journal OD
Crankshaft Connecting Rod Journal OD Wear Limit
Connecting Rod Bearing ID (Max)
Piston Pin Bushing ID
40.000-40.065 mm (1.5748-1.5774 in.)
40.100 mm (1.5787 in.)
0.040-0.085 mm (0.002-0.003 in.)
40.000-40.025 mm (1. 5748-1.5757 in.)
40.1 00 mm (1.5787 in.)
0.065-0.115 mm (0.003-0.005 in.)
40.000-40.025 mm (1.5748-1.5757 in.)
0.040-0.125 mm (0.002-0.005 in.)
39.97-39.98
(1.7311-1.7315 in.)
mm (0.828-0. 828 in.)
ENGINE - GAS SPECIFICATIONS
Piston Pin Bushing ID Wear Limit.
Piston Pin-to-Bushing Oil Clearance
Piston Pin-to-Bushing Clearance Wear Limit
Piston Ring Groove Side Clearance
Top Piston Ring
Top Piston Ring (Max)
Second Piston Ring .
Second Piston Ring (Max).
Oil Control Ring
Oil Control Ring (Max)
Piston Ring End Gap
Top Ring End Gap (Max)
Second Ring End Gap (Max).
Oil Control Ring End Gap (Max)
Piston
Piston Pin OD
Piston Pin OD Wear Limit
Piston Pin Bore ID
Piston Pin Bore ID Wear Limit.
Piston Pin-to-Bore Clearance
Piston Pin-to-Bore Wear Limit.
Piston OD Wear Limit.
Piston Measurement Distance
Piston-to-Cylinder Clearance (Max)
Cylinder Block
Cylinder Bore (Standard Size).
Cylinder Bore Wear Limit (Standard Size)
Piston-to-Cylinder Clearance (Max)
Cylinder Roundness.
Cylinder Roundness (Max)
0.25 mm (0.010 in.) Oversize Bore ID
0.25 mm (0.010 in.) Oversize Bore ID Wear Limit.
mm (0.831 in.)
0.000-0.018 mm (0.0000-0.0007 in.)
mm (0.0018 in.)
0.075-0.110 mm (0.0029-0.0043 in.)
0.030-0.065 mm (0.0012-0.0026 in.)
20.99-21.00
20.90 mm (0.823 in.)
(0.001 in.)
in.)
mm (2.852 in.)
Torque Specifications
ENGINE - GAS SPECIFICATIONS
NOTE: Use appropriate torque wrench which will read within the inch-pound range given, or convert inch-pounds to foot-pounds as follows: 12 inch-pounds = 1 foot-pound.
Camshaft Thrust Plate Cap Screw
Connecting Rod Cap Screw
Crankshaft Main Bearing Cap Screw
Cylinder Head Cap Screw
Initial
Final.
Rocker Arm Cover Special Nut
Rocker Arm Support Cap Screw and Nut.
Flywheel Cap Screw.
Clutch Cover Cap Screw
Timing Gear Housing Cap Screw
Timing Gear Housing Cover Cap Screw.
Crankshaft Pulley Cap Screw Torque.
Manifold
Intake Manifold Cap Screw
Carburetor Mounting Cap Screw.
Exhaust Manifold Cap Screw
Muffler Flange Nut
OIl Pan Cap Screws Threading in Block.
Oil Pan Cap Screws Threading in Aluminum.
Oil Pressure Switch
Oil Pump Attaching Cap Screw.
Oil Pressure Valve Spring Retaining Nut.
Spark Plug.
Starting Motor Mounting Cap Screw
Thermostat Cover Cap Screw.
Subframe Mounting Cap Screw
Coolant Pump
Plate Screw.
Pulley Cap Screw
Attaching Cap Screw
(78
ENGINE - GAS TOOLS AND MATERIALS
Tools and Materials
Special or Required Tools
Special or Required Tools
Tool NameTool No.Tool Use
Magnetic Follower Holder Kit
Reaming Tool (7.05 mm)
Valve Spring Compressor
Valve Guide Driver
Tachometer or Digital Pulse Tachometer
Pressure Test Kit
Clutch Alignment Tool
Compression Gauge
D15001NUUsed to hold cam followers away from camshaft.
D20020WIUsed to clean or size valve guides.
JDE138Used to remove and install valve springs.
JDE504Used to remove and install valve guides.
JT07270Used for low idle adjustment and to check fast idle.
JDG356Used to check fuel pump pressure.
JDG1331Used to align clutch disc.
JDM59Used for cylinder compression test.
ConnectorJT03349Used for oil pressure test.
Hose AssemblyJT03017Used for oil pressure test.
0-700 kPa (0100 psi) Gauge
JT07034Used for oil pressure test.
Ridge ReamerJT07277Removes ridge from top of cylinder bore.
Feeler GaugeNAUsed to measure valve clearance.
Dial IndicatorNAUsed for valve lift, end play, and backlash measurements.
PLASTIGAGE® Bearing Clearance
Measurement
Tool
Piston Ring Compressor
NAUsed to measure clearance.
Other Materials
Other Material
Part No.Part NamePart Use
NAAbrasive Sheets/ Pads Used to clean cylinder head.
TY24344 (U.S.)
Form-in-Place Gasket
Seals crankcase extension housing, rear oil seal case, timing gear cover, and flywheel housing to engine block. Seals oil pan to timing gear housing and engine block.
NAUsed to install pistons.
ENGINE - GAS DIAGNOSTICS
Diagnostics
Gas Engine Troubleshooting
Symptom: Engine Will Not Crank
(1) Is starting procedure being used correct for conditions?
Yes - Go to step (2).
No - Use correct procedure for conditions See the Operator’s Manual.
(2) Is battery 12.7 VDC or higher?
Yes - Go to step (3).
No - Charge and check battery. (See “Battery Test” on page274.)
(3) Are there open circuits in wiring?
Yes - Go to step (4).
No - Repair or replace as needed. (See “Common Circuit Tests” on page187.)
(4) Is starting motor functioning properly?
No - Repair or replace starting motor.
cCAUTION: Avoid injury! To avoid electric shock, DO NOT hold spark plug. Instead, make sure to hold plug cap.
Symptom:
Engine Hard to Start
(1) Does engine continue to run when key switch is released from the START position?
Yes - Go to step (2).
No - Ignition start diode may be faulty. (See “Diode Test” on page294.)
No - Ignition switch may be faulty. (See “Key Switch Test” on page284.)
(2) Perform spark output test. Is adequate spark available at all spark plugs?
Yes - Go to step (3).
No - Ignition coil or high-tension lead may be faulty. (See “Ignition Coil Test” on page294.)
No - Pulser coil may be faulty. (See “Pulser Coil Test” on page295.)
No - Start diode may be faulty. (See “Diode Test” on page294.)
Symptom: Engine Hard to Start
(3) Are spark plugs fouled or is insulation cracked?
Yes - Replace spark plugs.
No - Go to step (4) if problem continues..
(4) Is the fuel tank filled with fresh, clean fuel of the correct grade?
Yes - Go to step (5).
No - Fill the tank with fresh, clean fuel of the correct type. (See “Gasoline” on page16.)
(5) Are the fuel hoses and fuel filter free of obstructions?
Yes - Go to step (6).
No - Clear fuel lines and/or replace fuel filter.
(6) Is the fuel tank cap breather hole free of obstructions?
Yes - Go to step (7).
No - Clear obstructions from breather hole.
(7) Is choke operating correctly?
Yes - Go to step (8).
No - Adjust choke for proper operation.
(8) Does the fuel pump operate within specifications? (Perform fuel pump flow rate test. (See “Test Fuel Pump Flow” on page39.)
Yes - Go to step (9).
No - Replace the fuel pump. (See “Remove and Install Fuel Pump” on page45.)
(9) Is fuel shutoff solenoid operating properly? (Perform fuel shutoff solenoid test. (See “Fuel Shutoff Solenoid Test - Gasoline Engine” on page293.)
Yes - Go to step (10).
No - Replace fuel shutoff solenoid. (See “Inspect Carburetor” on page41.)
(10) Are air filter elements in good condition, not clogged?
Yes - Go to step (11).
No - Clean and/or replace air filter elements.
(11) Is the carburetor operating and/or adjusted properly?
Yes - Go to step (12).
No - See “Inspect Carburetor” on page41.
ENGINE - GAS DIAGNOSTICS
Symptom: Engine Hard to Start
(12) Is engine oil of correct viscosity and type?
Yes - Go to step (13).
No - Replace engine oil with oil of proper viscosity and type. Replace oil filter.
(13) Is engine compression within specifications? (Perform cylinder compression test. See “Test Cylinder Compression” on page37.)
No - Proceed as directed in “Results.”
cCAUTION: Avoid injury! To avoid electric shock, DO NOT hold spark plug. Instead, make sure to hold cap.
Symptom: Engine Malfunctions at Low Speed
(1) Perform spark output test. Is adequate spark available at all spark plugs?
Yes - Go to step (2).
No - Ignition coil or high-tension lead may be faulty. (See “Ignition Coil Test” on page294.)
No - Pulser coil may be faulty. (See “Pulser Coil Test” on page295.)
(2) Are spark plugs fouled or is insulation cracked?
Yes - Replace spark plugs.
No - Go to step (3) if problem continues..
(3) Are carburetor-to-intake manifold connections tight?
Yes - Go to step (4).
No - Flange nuts may be loose. Tighten flange nuts.
No - Gasket may be damaged. Replace gasket. (See “Remove and Install Carburetor” on page40.)
(4) Are the fuel hoses and fuel filter free of obstructions?
Yes - Go to step (5).
No - Clear fuel lines and/or replace fuel filter.
(5) Is the fuel tank cap breather hole free of obstructions?
Yes - Go to step (6).
No - Clear obstructions from breather hole.
Symptom:
Engine Malfunctions at Low Speed
(6) Start engine and run it at slow idle. Is exhaust free of unusual black smoke?
Yes - Go to step (7).
No - Check for plugged air filter elements.
No - Over-rich carburetor slow idle circuit. Inspect and repair as necessary.
No - Check for damaged float valve or misadjusted float. (See “Inspect Carburetor” on page41.)
No - Choke not opening completely.
(7) Gradually open throttle valve by hand. Does engine accelerate smoothly through all throttle positions?
Yes - Go to step (8).
No - Passages in carburetor may be plugged. Clean the carburetor.
(8) Stop engine and check valve clearance. Is clearance within specifications?
Yes - Go to step (9).
No - Adjust valve clearance. (See “Adjust Valve Clearance” on page36.)
(9) Is alignment of timing gears correct?
No - Align timing gears. (See “Remove and Install Camshaft” on page65.)
Symptom: Engine Runs Erratically
(1) Perform spark output test. Is adequate spark available at all spark plugs?
Yes - Go to step (2).
No - Ignition coil or high tension lead may be faulty. (See “Ignition Coil Test” on page294.)
No - Pulser coil may be faulty. (See “Pulser Coil Test” on page295.)
(2) Are spark plugs fouled or is insulation cracked?
Yes - Go to step (3).
No - Go to next step.
(3) Are carburetor-to-intake manifold connections tight?
Yes - Go to step (4).
No - Flange nuts may be loose. Tighten flange nuts.
No - Gasket may be damaged. Replace gasket. (See “Remove and Install Carburetor” on page40.)
