John Deere 9120, 9220, 9320, 9420, 9520, 9620 Tractor Service Manual TM1972 - PDF

John Deere Construction and Forestry

9120, 9220, 9320,9420, 9520 and 9620 Tractors Operation and Test

DIAGNOSIS AND TESTS MANUAL 4WD Articulated models 9120, 9220, 9320, 9420, 9520, 9620

TM1972, January 2013

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Table of contents

FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - General Specifications Group 15 - General References Section 211 - SERVICE CODES Group ACU - ACU Code Diagnostics Group AMS - AMS Code Diagnostics Group ASU - ASU Code Diagnostics Group ATC - ATC Code Diagnostics Group CCU - CCU Code Diagnostics Group ECU - ECU Code Diagnostics Group HCU - HCU Code Diagnostics Group ICU - ICU Code Diagnostics Group JDL - JDL Code Diagnostics Group PCU - PCU Code Diagnostics Group SCo - SCo Code Diagnostics Group SCS - SCS Code Diagnostics Group SCU - SCU Code Diagnostics Group SSU - SSU Code Diagnostics Group SUP - SUP Code Diagnostics Section 212 - OBSERVABLE SYMPTOMS Group 05 - Axles Group 15 - Electrical Group 16 - Ag Management Solutions (AMS) Group 20 - Hitch Group 25 - Heating, Ventilation, and Air Conditioning (Standard) Group 26A - Heating, Ventilation and Air Conditioning - CLIMATRAK™ (ATC) (—009999) Group 26B - Heating, Ventilation and Air Conditioning - CLIMATRAK™ (ATC) (010001—) Group 30 - Operator Station Group 35 - PowerShift Transmission Group 40 - Power Take-Off Group 45 - Selective Control Valve Group 50 - Steering Group 60 - Manual Shift Transmission Section 213 - SYSTEM DIAGNOSIS Group 50 - Powershift Transmission Group 55 - Manual Shift Transmission Group 60 - Steering System Group 61 - AutoTrac Steering System Group 70A - Hydraulic System (Standard) Group 70B - Hydraulic System (Scraper High Flow) Group 70C - Hydraulic System (Ag High Flow) Group 90 - Operator Station Section 220 - ENGINE Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 230 - FUEL AND AIR <- Go to Global Table of contents

TM1972-DIAGNOSIS AND TESTS MANUAL

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Group 20 - Theory of Operation Section 240 - ELECTRICAL Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 245 - CONTROL UNITS Group 05 - Codes and Addresses Group ACU - ACU References Group ASU - ASU References Group ATC - ATC References Group CCU - CCU References Group ECU - ECU References Group HCU - HCU References Group ICU - ICU References Group PCU - PCU References Group PRF - PrF References Group SCo - SCo References Group SCS - SCS References Group SCU - SCU References Group SSU - SSU References Group SUP - SUP References Section 246A - AG MANAGEMENT SOLUTIONS (AMS) — GREENSTAR Group GSS - Greenstar™ System References Section 246B - AG MANAGEMENT SOLUTIONS (AMS) — JDLINK™ Group 10A - Accessing Diagnostic Codes and Addresses Group 10B - Diagnostic Trouble Codes Group 10C - Diagnostic Addresses Group 15A - JDLINK™ Machine Messenger Diagnostics Section 246C - AG MANAGEMENT SOLUTIONS (AMS) — AUTOTRAC Group 05A - How to Use This Diagnostic Information Group 10A - Accessing Diagnostic Addresses and Codes Group 10B - Diagnostic Trouble Codes Group 10C - Diagnostic Addresses Group 15A - AutoTrac Identification Group 15B - AutoTrac Diagnostics - 9000 Series Factory Installed Group 15C - AutoTrac Diagnostics - 9000 Series Field Installed Group 15D - GREENSTAR™ Parallel Tracking Identification Group 15E - Parallel Tracking Diagnostics - 9000 Series Factory Installed Group 15F - Parallel Tracking Diagnostics - 9000 Series Field Installed Group 15G - GREENSTAR™ Display Diagnostics Group 15H - GREENSTAR™ Mobile Processor Diagnostics Group 15I - STARFIRE™ Receiver Diagnostics Group 15J - GREENSTAR™ KeyCard Diagnostics Group 15K - AutoTrac CAN Bus Identification Group 15L - AutoTrac CAN Bus Diagnostics - 9000 Series Factory Installed Group 15M - AutoTrac CAN Bus Diagnostics - 9000 Field Installed Group 15N - AutoTrac CCD Bus Identification Group 15O - AutoTrac CCD Bus Diagnostics - 9000 Series Factory Installed Group 15P - AutoTrac CCD Bus Diagnostics - 9000 Series Field Installed Group 15Q - AutoTrac Power Identification

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TM1972-DIAGNOSIS AND TESTS MANUAL

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Group 15R - AutoTrac Power Diagnostics - 9000 Series Factory Installed Group 15S - AutoTrac Power Diagnostics - 9000 Series Field Installed Group 15T - AutoTrac Status Identification Group 15U - AutoTrac Status Diagnostics - 9000 Series Factory Installed Group 15V - AutoTrac Status Diagnostics - 9000 Series Field Installed Group 15W - AutoTrac Steering Response Identification Group 15X - AutoTrac Steering Response Diag. - 9000 Series Factory Installed Group 15Y - AutoTrac Steering Response Diag. - 9000 Series Field Installed Group 15Z - AutoTrac Steering Control Unit Identification Group 15AA - AutoTrac Steering Control Unit Diag - 9000 Series Factory Installed Group 15AB - Steering Control Unit Diag - 9000 Series Field Installed Group 20A - Circuit Code Listing Group 20B - Connector Information Section 246D - AG MANAGEMENT SOLUTIONS (AMS) — FIELD DOC™ Group 15A - GPS Position and STARFIRESTARFIRE is a trademark of Deere & Company Receiver Operation and Tests Group 15B - FIELD DOCFIELD DOC is a trademark of Deere & Company Basic Operation and Tests Section 250 - POWERSHIFT TRANSMISSION Group 05 - Preliminary Checks Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 255 - MANUAL SHIFT TRANSMISSION Group 05 - Preliminary Checks Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 256 - DRIVE SYSTEMS Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 260 - STEERING AND BRAKES Group 05 - Preleminary Checks Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 270 - HYDRAULICS Group 05 - Preliminary Checks Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 290 - OPERATOR STATION Group 05 - Preliminary Checks Group 10 - Operational Checks

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TM1972-DIAGNOSIS AND TESTS MANUAL

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 299 - TOOLS Group 10 - Fabricated Tools Group 15 - Test Kits

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TM1972-DIAGNOSIS AND TESTS MANUAL

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TM1972-DIAGNOSIS AND TESTS MANUAL

GENERAL

(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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Section 210 page 2

TM1972-DIAGNOSIS AND TESTS MANUAL

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Section 210 - GENERAL Table of contents Group 05 - Safety ...................................................................................................................... 2 Recognize Safety Information ................................................................................................ 2 Handle Fluids Safely—Avoid Fires .......................................................................................... 2 Prevent Battery Explosions .................................................................................................... 3 Prepare for Emergencies ........................................................................................................ 3 Prevent Acid Burns ................................................................................................................. 5 Handle Agricultural Chemicals Safely .................................................................................... 7 Avoid High-Pressure Fluids ..................................................................................................... 9 Park Machine Safely ............................................................................................................... 9 Support Machine Properly .................................................................................................... 10 Wear Protective Clothing ..................................................................................................... 11 Work in Clean Area .............................................................................................................. 12 Service Machines Safely ....................................................................................................... 12 Service Accumulator Systems Safely ................................................................................... 13 Work In Ventilated Area ....................................................................................................... 13 Illuminate Work Area Safely ................................................................................................. 14 Replace Safety Signs ............................................................................................................ 15 Use Proper Lifting Equipment ............................................................................................... 15 Remove Paint Before Welding or Heating ............................................................................ 16 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 16 Keep ROPS Installed Properly ............................................................................................... 17 Avoid Harmful Asbestos Dust ............................................................................................... 18 Practice Safe Maintenance ................................................................................................... 19 Use Proper Tools .................................................................................................................. 21 Dispose of Waste Properly ................................................................................................... 21 Prevent Machine Runaway ................................................................................................... 22 Handle Starting Fluid Safely ................................................................................................. 23 Service Cooling System Safely ............................................................................................. 24 Stay Clear of Rotating Drivelines ......................................................................................... 25 Protect Against High Pressure Spray .................................................................................... 28 Construct Dealer-Made Tools Safely .................................................................................... 28 Clean Vehicle of Hazardous Pesticides ................................................................................. 29 Live With Safety ................................................................................................................... 29 Group 10 - General Specifications ........................................................................................ 31 Reference 210-10-001, General Specifications .................................................................... 31 Group 15 - General References ............................................................................................. 35 Service Equipment and Tools ............................................................................................... 35 Specifications ....................................................................................................................... 35 Reference 210-15-001, General Reference List ................................................................... 36 Reference 210-15-002, Bolt and Cap Screw Torque Values ................................................. 37 Reference 210-15-003, Glossary of Terms ........................................................................... 40 Reference 210-15-004, JIC Hydraulic Symbols ..................................................................... 45 Reference 210-15-005, Wiring Diagram and Schematic Information ................................... 48 Reference 210-15-006, Electrical Schematic Symbols ......................................................... 50 Reference 210-15-007, Reading Wiring Schematics and Diagrams ..................................... 53

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TM1972-DIAGNOSIS AND TESTS MANUAL

TM1972-DIAGNOSIS AND TESTS MANUAL

(g) by Belgreen

Reference 210-15-008, Visually Inspect Electrical System ................................................... 60 Reference 210-15-009, Seven Step Electrical Procedure With probe light or multimeter ....................................................................................................................................... 62 Reference 210-15-010, Using a Probe Light ......................................................................... 64 Reference 210-15-011, Circuit Types ................................................................................... 66 Reference 210-15-012, Circuit Malfunctions ........................................................................ 68 Reference 210-15-013, Troubleshooting Circuit Malfunctions .............................................. 72 Reference 210-15-014, Understanding Electrical vs. Electronic Circuits .............................. 77 Reference 210-15-015, Intermittent Electronic Problems .................................................... 80 Reference 210-15-016, Relay Circuit Types ......................................................................... 84 Reference 210-15-017, Using a Digital Multimeter .............................................................. 98 Reference 210-15-101, Troubleshooting Unresolved Electrical/Electronic Problems ......... 100

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TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

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.

Handle Fluids Safely—Avoid Fires

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Section 210 page 2

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Avoid Fires 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.

Prevent Battery Explosions

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).

Prepare for Emergencies

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Section 210 page 3

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

First Aid Kit 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.

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Section 210 - GENERAL

Group 05: Safety

Prevent Acid Burns

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 the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added. <- Go to Section TOC

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Section 210 - GENERAL

Group 05: Safety

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 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

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Section 210 page 6

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Handle Agricultural Chemicals Safely

Safety

Safety Chemicals used in agricultural applications such as fungicides, herbicides, insecticides, pesticides, rodenticides, and fertilizers can be harmful to your health or the environment if not used carefully.

Always follow all label directions for effective, safe, and legal use of agricultural chemicals.

Reduce risk of exposure and injury: Wear appropriate personal protective equipment as recommended by the manufacturer. In the absence of manufacturer′s instructions, follow these general <- Go to Section TOC

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Section 210 - GENERAL

Group 05: Safety

guidelines: Chemicals labeled ′Danger′ : Most toxic. Generally require use of goggles, respirator, gloves, and skin protection.

Chemicals labeled ′Warning′ : Less toxic. Generally require use of goggles, gloves, and skin protections.

Chemicals labeled ′Caution′ : Least toxic. Generally require use of gloves and skin protection.

Avoid inhaling spray or dusts.

Always have soap, water, and towel available when working with chemicals. If chemical contacts skin, hands, or face, wash immediately with soap and water. If chemical gets into eyes, flush immediately with water.

Wash hands and face after using chemicals and before eating, drinking, smoking, or urination.

Do not smoke or eat while applying chemicals.

After handling chemicals, always bathe or shower and change clothes. Wash clothing before wearing again.

Seek medical attention immediately if illness occurs during or shortly after use of checmials.

Keep chemicals in original containers. Do not transfer chemicals to unmarked containers or to containers used for food or drink.

Store chemicals in a secure, locked area way from human or livestock food. Keep children away.

Always dispose of containers properly. Triple rinse empty containers and puncture or crush containers and dispose of properly.

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Section 210 page 8

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Avoid High-Pressure Fluids

High Pressure Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting 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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Park Machine Safely

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Section 210 page 9

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Remove the Key Before working on the machine: Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

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TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

Wear Protective Clothing

Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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Section 210 page 11

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

Service Machines Safely

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Section 210 page 12

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Service Accumulator Systems Safely

Hydraulic Accumulator Escaping fluid or gas from pressurized hydraulic accumulator systems can cause serious injury. Extreme heat can cause the accumulator to burst, and pressurized lines can be accidentally cut. Do not weld or use a torch near a pressurized accumulator or pressurized line.

Relieve pressure from the hydraulic system before removing accumulator. Never attempt to relieve hydraulic system or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired.

Work In Ventilated Area

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Section 210 page 13

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Section 210 - GENERAL

Group 05: Safety

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Illuminate Work Area Safely

Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an <- Go to Section TOC

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Section 210 - GENERAL

Group 05: Safety

accidentally broken bulb can ignite spilled fuel or oil.

Replace Safety Signs

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

Proper Lifting Equipment

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TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Section 210 - GENERAL

Group 05: Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray 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 accidentally burst when heat goes beyond the immediate flame area.

Keep ROPS Installed Properly

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Section 210 page 17

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Roll-Over Protective Structure Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for your tractor.

Any alteration of the ROPS must be approved by the manufacturer.

Avoid Harmful Asbestos Dust

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Section 210 page 18

TM1972-DIAGNOSIS AND TESTS MANUAL

Section 210 - GENERAL

Group 05: Safety

Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

Practice Safe Maintenance

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Section 210 - GENERAL

Group 05: Safety

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments <- Go to Section TOC

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Section 210 - GENERAL

Group 05: Safety

on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

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Section 210 - GENERAL

Group 05: Safety

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.

Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Prevent Machine Runaway

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Section 210 - GENERAL

Group 05: Safety

Machinery Runaway Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.

Handle Starting Fluid Safely

Store Safely

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Section 210 - GENERAL

Group 05: Safety

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Service Cooling System Safely

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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Section 210 - GENERAL

Group 05: Safety

Stay Clear of Rotating Drivelines

Rotating Drivelines

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Section 210 - GENERAL

Group 05: Safety

Drivelines Entanglement in rotating driveline can cause serious injury or death.

Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

Wear close fitting clothing. Stop the engine and be sure that PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

Do not install any adapter device between the tractor and the primary implement PTO drive shaft that will allow a 1000 rpm tractor shaft to power a 540 rpm implement at speeds higher than 540 rpm.

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Section 210 - GENERAL

Group 05: Safety

Do not install any adapter device that results in a portion of the rotating implement shaft, tractor shaft, or the adapter to be unguarded. The tractor master shield shall overlap the end of the splined shaft and the added adaptor device as outlined in the table.

Stay Clear of Rotating Drivelines PTO

Diameter

Spline

n ± 5 mm (0.20 in.)

Type 1

35 mm (1.378 in.)

s6

85 mm (3.35 in.)

2

35 mm (1.378 in.)

21

85 mm (3.35 in.)

3

45 mm (1.772 in.)

20

100 mm (4.00 in.)

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TM1972-DIAGNOSIS AND TESTS MANUAL

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