REPAIR MANUAL - JOHN DEERE TRACTORS TM1623 PDF DOWNLOAD

John Deere Construction and Forestry

9100, 9200, 9300, 9400, 9120, 9220, 9320, 9420, 9520 and 9620 Tractors Repair

REPAIR MANUAL 4WD Articulated models 9120, 9220, 9320, 9420, 9520, 9620

TM1623, September 2010

TM1623-REPAIR MANUAL

(g) by Belgreen

Table of contents

FOREWORD NOTICE TO THE DEALER DEALER PREDELIVERY INFORMATION FORM Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Information Section 20 - ENGINE Group 00 - Component Removal and Installation Group 05 - Engine Repair Section 30 - FUEL, AIR, AND COOLING SYSTEMS Group 05 - Diesel Fuel System Group 10 - Air Intake and Exhaust Systems Group 15 - Engine Cooling System Group 20 - Oil Coolers Section 40 - ELECTRICAL Group 05 - Connectors Group 10 - Wiring Harness Routings Group 15 - Charging Circuit Group 20 - Starting Circuit Group 25 - Relays, Fuses, Solenoids, and Switches Group 30 - Monitoring Systems and Sensors Group 35 - Armrest Control Group 40 - Implement and Accessory Connectors Group 45 - Convenience and Accessory Components Section 50 - 18-SPEED POWER SHIFT TRANSMISSION (9020) Group 00 - Component Removal and Installation Group 05 - In Tractor Repair Group 10 - Transmission Repair Group 15 - Transmission Cleanup Group 20 - Clutch Control Section 52 - 12-SPEED POWER SHIFT TRANSMISSION (9000) Group 00 - Component Removal and Installation Group 05 - Clutch Control Group 10 - Transmission Oil Filter Relief Valve Housing and Oil Pump Group 15 - Transmission Pressure Regulating Valve Group 20 - On-Off and Modulating Shift Solenoids Group 25 - 8-Inch Clutch Assembly Group 30 - Lower 7-Inch Clutch Assembly Group 35 - Upper 7-Inch Clutch Assembly Group 40 - Compound Shaft Assembly Group 45 - 9-Inch Clutch Assembly Group 50 - Front and Rear Housings Group 55 - Transmission Cleanup Section 55 - MECHANICAL SHIFT TRANSMISSION (MST) Group 00 - Component Removal and Installation Group 05 - Transmission Oil Filter Relief Valve Housing Group 10 - Transmission Control Valve Housing Group 15 - Transmission Pump Group 20 - Transmission Front Cover <- Go to Global Table of contents

TM1623-REPAIR MANUAL

TM1623-REPAIR MANUAL

(g) by Belgreen

Group 25 - Hi-Lo Clutch and Brake (24-Speed) Group 30 - Hi-Lo Planetary (24-Speed) Group 35 - Spacer Housing (24-Speed) Group 40 - Traction Clutch Group 45 - Transmission Gear Drives Group 50 - Transmission Cleanup Group 55 - Shift Levers and Linkage Section 56 - DRIVE SYSTEMS Group 00 - Component Removal and Installation Group 05 - Engine Coupler Group 10 - Drive Shafts Group 15 - PTO Clutch Group 20 - PTO Clutch Valve and Linkage Group 25 - PTO Drop Box Section 57 - AXLES Group 00 - Component Removal and Installation Group 02 - Park Brake Group 03 - Repair Preparation Group 05 - Input Housing Group 10 - Differential Group 15 - Final Drives Group 20 - Brakes Section 60 - STEERING AND BRAKES Group 05 - Steering Column Group 10 - Steering Control Valve Group 15 - Steering Cylinders Group 20 - Brake Valve Group 25 - Park Brake Section 70 - HYDRAULICS Group 00 - Component Removal and Installation Group 05 - Hydraulic System Repair Group 10 - Hydraulic Pump Group 15 - Axle Lubrication and Charge Pumps Group 20 - Filter Housings and Control Valves Group 25 - Hitch Valve, Selective Control Valves, and Couplers—9000 Series Group 30 - Hitch Valve, Selective Control Valves, and Couplers—9020 Series Group 35 - High-Flow Selective Control Valve—Scraper Group 40 - Hitch Section 80 - MISCELLANEOUS Group 05 - Hood and Side Panels Group 10 - Heavy-Duty Wheels—9020 Tractors Section 90 - OPERATOR STATION Group 00 - Component Removal and Installation Group 05 - Heating, Ventilating, and Air Conditioning (HVAC) Group 10 - Air Conditioning System Group 15 - Air Suspension Seat (S.N. —030000) Group 20 - Air Suspension Seat (S.N. 030001— ) and 9020 Series Group 25 - ACTIVE SEAT™ Group 30 - Armrest Group 35 - Cab Door and Windshield

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TM1623-REPAIR MANUAL

TM1623-REPAIR MANUAL

(g) by Belgreen

Section 95 - HINGE AND GUDGEON Group 05 - Hinge Group 10 - Gudgeon Section 99 - DEALER FABRICATED TOOLS Group 05 - Fabricated Tools

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TM1623-REPAIR MANUAL

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TM1623-REPAIR MANUAL

TM1623-REPAIR MANUAL

(g) by Belgreen

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction.

At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM1623-REPAIR MANUAL

TM1623-REPAIR MANUAL

(g) by Belgreen

Notice to the Dealer This is a complete revision of TM1623 Repair Technical Manual for 9100, 9200, 9300, and 9400 Tractors. It also covers 9120, 9220, 9320, 9420, and 9520 Tractors.

Discard TM1623 dated 14OCT04.

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TM1623-REPAIR MANUAL

GENERAL INFORMATION

(g) by Belgreen

Dealer Predelivery Information Form The John Deere Predelivery Form, when properly filled out and signed by dealer, verifies predelivery and delivery services were satisfactorily performed.

Because of the shipping factors involved, plus extra finishing touches necessary to promote customer satisfaction, there are certain predelivery services that must be performed by the dealer. These services are listed on the predelivery form with the tractor.

Perform all services listed and check each job off as it is completed. Fill form out completely and sign it.

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Section 10 page 2

TM1623-REPAIR MANUAL

TM1623-REPAIR MANUAL

(g) by Belgreen

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ...................................................................................................................... 2 Recognize Safety Information ................................................................................................ 2 Follow Safety Instructions ...................................................................................................... 2 Practice Safe Maintenance ..................................................................................................... 3 Protect Against High Pressure Spray ...................................................................................... 5 Handle Fluids Safely—Avoid Fires .......................................................................................... 5 Prevent Battery Explosions .................................................................................................... 6 Prepare for Emergencies ........................................................................................................ 7 Prevent Acid Burns ................................................................................................................. 8 Handle Agricultural Chemicals Safely .................................................................................. 10 Avoid High-Pressure Fluids ................................................................................................... 11 Park Machine Safely ............................................................................................................. 12 Support Machine Properly .................................................................................................... 13 Wear Protective Clothing ..................................................................................................... 14 Work in Clean Area .............................................................................................................. 15 Service Machines Safely ....................................................................................................... 15 Work In Ventilated Area ....................................................................................................... 16 Illuminate Work Area Safely ................................................................................................. 16 Replace Safety Signs ............................................................................................................ 17 Use Proper Lifting Equipment ............................................................................................... 17 Service Tires Safely .............................................................................................................. 18 Avoid Harmful Asbestos Dust ............................................................................................... 20 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 20 Remove Paint Before Welding or Heating ............................................................................ 21 Use Proper Tools .................................................................................................................. 22 Construct Dealer-Made Tools Safely .................................................................................... 23 Dispose of Waste Properly ................................................................................................... 23 Live With Safety ................................................................................................................... 24 Service Tires Safely .............................................................................................................. 25 Protect Against Noise ........................................................................................................... 26 Keep ROPS Installed Properly ............................................................................................... 26 Service Accumulator Systems Safely ................................................................................... 27 Wait Before Opening High-Pressure Fuel System ................................................................. 28 Group 10 - General Information ............................................................................................ 29 General Specifications—9000 Series .................................................................................... 29 General Specifications—9020 Series .................................................................................... 31 General Specifications—9000 and 9020 Series .................................................................... 33 Identify Zinc-Flake Coated Fasteners ................................................................................... 34 Metric Bolt and Screw Torque Values ................................................................................... 36 Unified Inch Bolt and Screw Torque Values .......................................................................... 38 Sealants and Adhesives Cross-Reference Chart ................................................................... 40 Glossary of Terms ................................................................................................................ 42

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TM1623-REPAIR MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol This is a 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 operating practices.

Follow Safety Instructions

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Section 10 page 2

TM1623-REPAIR MANUAL