PDF FILE DOWNLOAD TM2137 JOHN DEERE 4120 COMPACT UTILITY TRACTOR WITHOUT CAB

tm2137 - Compact Utility Tractors 4120 PIN (120101610000), 4320 PIN (130101-620000), 4520 PIN (150101650000), 4720 PIN (170101-670000) (Without Cab) Technical Manual Main Sections Manual Description Safety Safety

Specifications & Information General Specifications O-Ring Seal Service Recommendations Fuels and Lubricants Coolant Specifications Serial Number Locations

Engine - Diesel Specifications Tools and Materials Theory of Operation Theory of Operation (Air and Fuel) Diagnostics Tests and Adjustments Repair Cylinder Head and Valves Cylinder Block, Pistons, and Rods

Crankshaft, Main Bearings and Flywheel Camshaft, Balancer Shafts and Timing Gear Train Lubrication System Cooling System Air Intake and Exhaust System Fuel System Starting and Charging Systems

Electrical General Information Specifications Component Location Schematics and Harnesses Troubleshooting Operation and Diagnostics Tests and Adjustments Repair

Electrical - European Specifications Component Location Schematics and Harnesses Troubleshooting Operation and Diagnostics

Power Train - PRT Specifications Component Location Theory of Operation

Tests and Adjustments Repair

Power Train - Hydrostatic Specifications Component Location Schematics Theory of Operation Diagnostics Tests and Adjustments Repair

Power Train - Final Drive Specifications Component Location Theory of Operation Diagnostics Tests and Adjustments Repair PTO Theory of Operation PTO Repair

Hydraulics Specifications Component Location Schematics & Harnesses Theory of Operation Diagnostics Tests and Adjustments

Repair

Steering Specifications Component Location Theory of Operation Diagnostics Tests and Adjustments Repair

Brakes Specifications Component Location Theory of Operation Diagnostics Tests and Adjustments Repair

Miscellaneous Specifications Repair

Table of Contents

tm2137 - Compact Utility Tractors 4120 PIN (120101610000), 4320 PIN (130101-620000), 4520 PIN (150101650000), 4720 PIN (170101-670000) (Without Cab) Table of Contents Manual Description Section : Safety Group : Safety Recognize Safety Information Understand Signal Words Replace Safety Signs Handle Fluids Safely - Avoid Fires Use Care In Handling and Servicing Batteries Prevent Battery Explosions Prevent Acid Burns Wear Protective Clothing Use Care Around High-pressure Fluid Lines Service Machines Safely Use Proper Tools Park Machine Safely Support Machine Properly and Use Proper Lifting Equipment Work In Clean Area Using High Pressure Washers Illuminate Work Area Safely Work In Ventilated Area Warning: California Proposition 65 Warning Remove Paint Before Welding or Heating Avoid Harmful Asbestos Dust Service Tires Safely

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Table of Contents Avoid Injury From Rotating Blades, Augers and PTO Shafts Service Cooling System Safely Dispose Of Waste Properly Handle Chemical Products Safely Live With Safety

Section : Specifications & Information Group : General Specifications Metric Fastener Torque Values Metric Fastener Torque Values—Grade 7 Inch Fastener Torque Values Gasket Sealant Application

Group : O-Ring Seal Service Recommendations Face Seal Fittings with Inch Stud Ends Torque Face Seal Fittings with Metric Stud Ends Torque O-Ring Face Seal Fittings O-Ring Boss Fittings

Group : Fuels and Lubricants Diesel Fuel Specifications Diesel Fuel Lubricity Diesel Fuel Storage Engine Oil Engine Break–in Oil Alternative Lubricants Synthetic Lubricants Lubricant Storage Mixing Of Lubricants Chassis Grease Transaxle Oil

Group : Coolant Specifications

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Table of Contents Engine Coolant Engine Coolant Drain Interval

Group : Serial Number Locations Machine Product Identification Number Engine and Turbocharger Serial Numbers

Section : Engine - Diesel Group : Specifications Engine Specifications Cylinder Head and Valves Specifications Cylinder Block, Pistons, and Rods Specifications Crankshaft, Main Bearings, and Flywheel Specifications Camshaft, Balancer Shafts and Timing Gear Train Specifications Lubrication System Specifications Cooling System Specifications Air Intake and Exhaust System Specifications Starting and Charging Systems Specifications Fuel System Engine Mounting Specifications

Group : Tools and Materials Engine Rebuild Essential Tools Engine Rebuild Service Equipment and Tools Cylinder Head and Valves Essential Tools Cylinder Head and Valves Other Materials Cylinder Block, Pistons, and Rods Essential Tools Crankshaft, Main Bearings and Flywheel Essential Tools Crankshaft, Main Bearings and Flywheel Service Equipment and Tools Crankshaft, Main Bearings and Flywheel Other Materials Camshaft and Timing Gear Train Essential Tools Lubrication System Essential Tools

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Table of Contents Base Engine Diagnostic Tools Fuel System Observable Diagnostic Tools

Group : Theory of Operation General Engine Operation Lubrication System Operation Coolant System Operation Air

Intake

and

Exhaust

System

Operation Air Cleaner Operation Turbocharger Operation Turbocharger Lubrication

Group : Theory of Operation (Air and Fuel) Fuel System Operation Fuel Supply Pump Fuel Filter/Water Separator Operation Governor Operation Integrated Fuel System (IFS) Operation Light Load and Speed Advance Operation Cold Start Advance Operation Glow Plug Cold Start Aid Operation

Group : Diagnostics About This Group of the Manual Guideline for Acceptable Oil Consumption L1 - Excessive Oil Consumption L2 - Engine Oil Pressure Low L3 - Engine Oil Pressure High C1 - Coolant Temperature Above Normal C2 - Coolant Temperature Below Normal C3 - Coolant in Oil or Oil in Coolant E1 - Engine Cranks/Won’t Start

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Table of Contents E2 - Engine Misfires/Runs Irregularly E3 - Engine Does Not Develop Full Power E4 - Excessive White Exhaust Smoke E5 - Excessive Black Or Gray Exhaust Smoke E6 - Engine Will Not Crank E7 - Engine Idles Poorly E8 - Abnormal Engine Noise F1 - Fuel Supply System Check F2 - Excessive Fuel Consumption F3 - Fuel in Oil

Group : Tests and Adjustments Test Engine Compression Pressure Test Engine Cranking Speed Dynamometer Test Engine Oil Consumption Check Engine Oil Pressure Check for Excessive Engine Crankcase Pressure (Blow-By) Check for Turbocharger Oil Seal Leak Inspect Thermostat and Test Opening Temperature Pressure Test Cooling System and Radiator Cap Check for Head Gasket Failures Check and Service Cooling System Check Air Intake System Measure Intake Manifold Pressure (Turbocharger Boost) Check for Intake and Exhaust Restrictions Test for Intake Air Leaks Check for Exhaust Air Leaks (Turbocharger) Glow Plug Operation Cylinder Misfire Test Check Fuel Supply Quality

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Table of Contents Test for Fuel Drain Back Test Air in Fuel Bleed Fuel System Measure Fuel Transfer Pump Pressure Bench Test Fuel Transfer Pump Check Cold Start Advance Operation Check Fuel Shut-Off Solenoid Operation Check and Adjust Fast Idle Speed Check and Adjust Slow Idle Speed

Group : Repair Engine Removal and Installation Engine Disassembly Sequence Engine Assembly Sequence Engine Break-In Guidelines Perform Engine Break-In

Group : Cylinder Head and Valves Cylinder Head - Exploded View Remove Rocker Arm Cover Remove Cylinder Head Disassemble and Inspect Rocker Arm Assembly Inspect, Remove, and Install Glow Plugs and Wire Harness Measure Valve Recess in Cylinder Head Preliminary Cylinder Head and Valve Checks Remove Valve Assembly Inspect and Measure Valve Springs Clean Valves Inspect and Measure Valves Grind Valves Head Gasket Inspection and Repair Sequence

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Table of Contents Inspect and Clean Cylinder Head Check Cylinder Head Flatness Knurl Valve Guides Clean and Inspect Valve Seats Grind Valve Seats Install Valves Inspect

and

Clean

Exhaust

Manifold Install Cylinder Head Install Rocker Arm Assembly

Group : Cylinder Block, Pistons, and Rods Connecting Rods - General Information Preliminary Cylinder Block, Pistons, and Rod Checks Remove Pistons and Connecting Rod Assembly Disassemble Piston and Rod Assembly Clean Pistons Visually Inspect Pistons Check Piston Ring Groove Wear Measure Piston Pin Bore Measure Piston Skirt Determine Piston-to-Cylinder Bore Clearance Deglaze Cylinder Bores Inspect and Measure Connecting Rod Bearings (Rods Removed from Engine) Inspect and Measure Connecting Rod Bearings (Rod & Crankshaft in Engine) Inspect Rod and Cap Inspect Piston Pins and Bushings Measure Rod Center-to-Center Bores Inspect and Clean Cylinder Block Measure Cylinder Block Main Bearing Bore Measure Camshaft Follower Machined Bore Measure Camshaft Bushing Bores in Block

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Table of Contents Inspect and Measure Cylinder Bore Measure Cylinder Block Top Deck Flatness Remove,

Inspect,

and

Install

Piston

Cooling

Orifices Assemble Piston and Connecting Rod Install Piston Rings Install Piston and Connecting Rod Assembly Torque-Turn Connecting Rod Cap Screws Check Engine Rotation for Excessive Tightness Measure Piston Protrusion Complete Final Assembly

Group : Crankshaft, Main Bearings and Flywheel Crankshaft and Main Bearing Failure Analysis Remove Crankshaft Pulley Inspect Pulley and Wear Sleeve Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover) Install Crankshaft Pulley Check Crankshaft End Play Check Flywheel Face Flatness Check Pilot Bearing Bore Concentricity Remove Flywheel Replace Flywheel Ring Gear Remove Flywheel Housing Remove Crankshaft Rear Oil Seal and Housing Clean and Inspect Crankshaft Flange Install Crankshaft Rear Oil Seal Housing Install Crankshaft Rear Oil Seal Remove Crankshaft Main Bearings Check Main Bearing Oil Clearance Remove Crankshaft Inspect Crankshaft

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Table of Contents Measure Crankshaft Journals and Main Bearing ID Measure Main Thrust Journal Width and Thrust Washers Measure Assembled ID of Main Bearing Caps Install Main Bearings, Thrust Washers and Crankshaft Install Flywheel Housing Install Flywheel

Group : Camshaft, Balancer Shafts and Timing Gear Train Remove Timing Gear Cover Remove Balancer Shafts Inspect and Measure Balancer Shaft Bushings and Journals Inspect Balancer Shaft Gears and Thrust Plates Remove, Inspect and Install Balancer Idler Gears and Shafts Measure Idler Gear Bushing and Shaft Remove Balancer Bushings Install Balancer Bushings Install Balancer Shafts Remove Governor Assembly and Camshaft Drive Gear Remove Camshaft Visually Inspect Camshaft Inspect and Measure Camshaft Bushing ID and Journal OD Remove and Install Camshaft Bushings Measure Camshaft Lobe Height Inspect Camshaft Followers Install Camshaft Install and Time Camshaft Drive Gear Install Governor Assembly Clean and Inspect Timing Gear Cover Install Timing Gear Cover

Group : Lubrication System

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Table of Contents General Lubrication System Information Remove Oil Cooler Install Oil Cooler Remove and Install Oil Pan Remove and Install Oil Pressure Regulating Valve Remove, Inspect, and Install Oil Pick-up Tube Assembly Remove, Inspect and Install Oil Pump Remove and Install Oil Dipstick Tube with Oil Pan Installed

Group : Cooling System Remove and Install Thermostat Test Thermostat Replacing Fan and Alternator Belt Remove and Install Automatic (Spring) Belt Tensioner Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner) Remove Coolant Pump Inspect and Clean Coolant Pump Parts Install Coolant Pump Cooling System Deaeration Inspect and Install Fan Assembly Remove Fan Bearing Install Fan Bearing

Group : Air Intake and Exhaust System Extending Turbocharger Life Remove Turbocharger Turbocharger Failure Analysis Turbocharger Inspection Repair Turbocharger Prelube Turbocharger Install Turbocharger

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Table of Contents Remove, Inspect, and Install Exhaust Manifold Remove, Inspect, and Install Intake Manifold

Group : Fuel System Remove and Install Fuel Supply Pump Remove and Inspect Integrated Fuel System (IFS) Install Integrated Fuel System (IFS) Remove and Install Fuel Rail Check Valve Remove and Install Governor Lever Assembly Remove and Install Throttle Control Assembly Remove and Install Full Load Stop Screw Remove and Install Idle Bias Adjustment Screw Remove and Install Fuel Shut-Off Solenoid Remove and Install Aneroid

Group : Starting and Charging Systems Remove and Install Starter Remove and Install Alternator

Section : Electrical Group : General Information Reading Electrical Schematics Theory

Of

Information

Operation Diagnostic

Information Wire Color Abbreviation Chart Common Circuit Tests Conductors For 12 Volt Circuits

Group : Specifications System Specifications Tools Other Materials

Group : Component Location

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Table of Contents Main Machine Load Center Display Panel

Group : Schematics and Harnesses Main Schematic and Wiring Harness Legend - PRT and eHydro eHydro - Schematic and Wiring Harness Legend W1 Main Electrical Schematic W9 eHydro and Cruise Control Electrical Schematic (1 of 2) W1 Main Wiring Harness W1 Main Wiring Harness Color Codes W2 Headlight Wiring Harness W2 Headlight Wiring Harness Color Codes W3 and W4 Jumper Plug W7 Right Rear Lights Wiring Harness W7 Right Rear Lights Wiring Harness Color Codes W8 Left Rear Lights Wiring Harness W8 Left Rear Lights Wiring Harness Color Codes W9 eHydro Wiring Harness W9 eHydro Wiring Harness Color Codes W10 Proportional Valve Wiring Harness W10 Proportional Valve Wiring Harness Color Codes W11 Cruise Control Wiring Harness (standard) W11 eHydro Cruise Control Wiring Harness Color Codes (standard) W12 Cruise Control Wiring Harness (optional) W12 eHydro Cruise Control Wiring Harness Color Codes (optional)

Group : Troubleshooting Display Panel Fault Codes Display Panel Fault Code Chart

Group : Operation and Diagnostics

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Table of Contents Power Circuit Operation Power Circuit Electrical Schematic - W1 PRT and eHydro Power Circuit Electrical Schematic - W9 eHydro Power Circuit Diagnosis Cranking Circuit Operation Cranking Circuit Electrical Schematic Cranking Circuit Diagnosis Glow Plug and Light Circuit Operation Glow Plug and Light Circuit Electrical Schematic Glow Plug and Light Circuit Diagnosis Fuel Supply/Engine Shutoff Circuit Operation Fuel Supply/Engine Shutoff Circuit Electrical Schematic Fuel Supply/Engine Shutoff Circuit Diagnosis Charging Circuit Operation Tachometer Circuit Operation Hour Meter Circuit Operation Charging,

Tachometer

Schematic

Charging,

and

Hour

Tachometer

Meter and

Circuit

Hour

Diagnosis Rear PTO Circuit Operation Rear PTO Circuit Electrical Schematic Rear PTO Circuit Diagnosis MFWD Circuit Operation MFWD Circuit Electrical Schematic MFWD Circuit Diagnosis Light Circuit Operation Lights Circuit Electrical Schematic Lights Circuit Diagnosis Turn Signal Lights Circuit Operation Turn Signal Lights Circuit Electrical Schematic Turn Signal Lights Circuit Diagnosis

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Electrical

Meter

Circuit

Table of Contents Display Panel Operation Display Panel Diagnosis Display Mode Switch Circuit Operation Display Mode Switch Circuit Electrical Schematic Display Mode Switch Circuit Diagnosis eHydro - eMatchOS Electronic Drive Controller eHydro - Forward Drive Circuit Operation eHydro - Forward Drive Circuit Electrical Schematic eHydro - Forward Drive Circuit Diagnosis eHydro - Reverse Drive Circuit Operation eHydro - Reverse Drive Circuit Electrical Schematic eHydro - Reverse Drive Circuit Diagnosis eHydro - Cruise Control Circuit Operation (standard) eHydro - Cruise Control Circuit Electrical Schematic (standard) eHydro - Cruise Control Circuit Diagnosis (standard) eHydro - Cruise Control Circuit Operation (optional) eHydro - Cruise Control Circuit Electrical Schematic (optional) eHydro - Cruise Control Circuit Diagnosis (optional) eHydro - Load Match and Motion Match Circuit Operation eHydro - Load Match and Motion Match Circuit Electrical Schematic eHydro - Load Match and Motion Match Control Circuit Diagnosis

Group : Tests and Adjustments Ground Circuit Test Battery Voltage and Specific Gravity Test Battery - Charge Battery - Load Test Alternator Regulated Voltage Test Alternator Test and Inspection Regulated Amperage and Voltage Test Starting Motor Solenoid Test

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Table of Contents Starting Motor Amperage Draw Test Starting Motor No-Load Amperage Draw and RPM Test Fuse Test Glow Plug Test Engine Coolant Temperature Sensor Test Engine Oil Pressure Switch Test Relay Test Key Switch Test Light Switch Test Sensing Switch Test Turn Signal Switch Test Hazard Switch Test Rear PTO Switch Test Rear PTO Solenoid Test Seat Switch Test Cruise/Max Speed Switch Test - eHydro Res/+, Set/- Switch Test - eHydro Brake and Park Brake Switch Test Air Filter Restriction Switch Test Fuel Gauge Sensor Test Fuel Shutoff Solenoid Test Load Match Switch Test - eHydro Motion Match Switch Test - eHydro Display Mode Switch Test Proportional Drive Solenoid Test - eHydro Horn Switch Test Configure the Display Editing Tire Size Value Editing Motion Match Settings - eHydro Editing Load Match Settings - eHydro

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Table of Contents Entering Diagnostic and Calibration Modes eHydro - Electronic Drive Controller System Calibration eHydro - Single Sensor Calibration Test Kit eHydro - Throttle Position Sensor Test and Adjustment eHydro - Forward and Reverse Pedal Sensor Test and Adjustment eHydro - MFWD Speed Sensor Test

Group : Repair Throttle Position Sensor Removal and Installation Electronic

Drive

Controller

Removal

and

Installation Alternator Removal and Installation Alternator Disassembly and Assembly Fuel Gauge Sensor Removal and Installation

Section : Electrical - European Group : Specifications System Specifications Tools Other Materials

Group : Component Location Main Machine Load Center Display Panel

Group : Schematics and Harnesses Main Schematic and Wiring Harness Legend - PRT and eHydro eHydro - Schematic and Wiring Harness Legend W1 Main Electrical Schematic (1 of 4) W9 eHydro and Cruise Control Electrical Schematic (1 of 2) W1 Main Wiring Harness W1 Main Wiring Harness Color Codes

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