John Deere 1023E, 1025R, 1026R Utility Tractor Technical Repair Manual TM149119 PDF

1023E, 1025R and 1026R Compact Utility Tractor

TECHNICAL MANUAL 1023E, 1025R, and 1026R Compact Utility Tractors (S.N. HJ100001— ) TM149119 22JUN17

John Deere Augusta Works PRINTED IN U.S.A.

(ENGLISH)

Introduction 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.

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.

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

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.

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.

DX,TMIFC -19-15APR14-1/1

TM149119 (22JUN17)

073117

PN=2

Contents Section 10—General Information

Group 10—Seat and Support Group 15—Control Console Group 20—Roll-Gard Group 25—Open Operator Station Components Group 30—Fenders

Group 05A—Safety Group 05B—General References Group 05C—Technical Specific References Group 05D—Fuel and Lubricants Group 05E—Serial Number Locations

Section 211—Diagnostic Trouble Codes

Section 20—Engine Repair

Group 05—General References Group 10—Diagnostic Display Messages

Group 05—Engine Group 10—Cooling System

Section 212—Observable Symptoms and System Diagnostics

Section 30—Fuel, Air Intake, and Exhaust Repair

Group 05—General References Group 20—Engine System Diagnostics Group 30—Fuel, Air Intake, Exhaust, and Cooling System Diagnostics Group 40—Electrical System Diagnostics Group 50—Drive Systems and Transmission System Diagnostics Group 60—Steering and Brakes System Diagnostics Group 70—Hydraulic System Diagnostics

Group 05—Fuel Group 10—Air Intake Group 20—Exhaust

Section 40—Electrical Repair Group 05—Connectors Group 10—Battery, Starter and Alternator Group 15—Electrical System Components

Section 50—Drive Systems and Transmission Repair Group 10—Power Train Group 15—MFWD Group 20—Differential Group 25—PTO

Section 60—Steering and Brake Repair Group 05—Steering Group 10—Brake

Section 220—Engine Operation, Test, and Adjustments Group 05—General References Group 10—Calibrations, Preliminary Checks and Operational Checks Group 20—Theory of Operation Group 40—Component and Connector Information Group 50—Tests and Adjustments

Section 230—Fuel , Air Intake, Exhaust, and Cooling Operation, Test, and Adjustments

Section 70—Hydraulics Repair

Group 05—General References Group 10—Calibrations, Preliminary Checks and Operational Checks Group 20—Theory of Operation Group 40—Component and Connector Information Group 50—Tests and Adjustments

Group 10—Hydraulic Pump and Filter Group 15—Rockshaft Group 20—Range Control and Three Point Hitch Group 25—Selective Control Valve Group 30—Hydraulic Lines

Section 80—Miscellaneous Repair

Section 240A—Electrical General and Theory of Operation

Group 10—Hood and Side Panels Group 15—Wheels Group 20—Mid-Mount Lift

Group 05—General References Group 20AA—Starting and Charging Group 20BA—Lighting—Without License Light Group 20BB—Lighting—With License Light Group 20EA—Instrument Cluster Control (ICC)

Section 90—Cab/Open Operator’s Station Repair

Continued on next page

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

COPYRIGHT © 2017 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2012, 2015, 2016

TM149119 (22JUN17)

i

073117

PN=1

Contents

Section 240B—Electrical Schematics Group 05—General References Group 30AA—Starting and Charging (SE1) Group 30BA—Lighting—Without License Light (SE2A) Group 30BB—Lighting—With License Light (SE2B) Group 30BC—Brake Switch, Horn, And Rear Trailer Connector (SE2C) Group 30CA—Instrument Cluster Control (ICC) (SE3) Group 30DA—Kits (SE4) Group 30EA—Electrical Harness Diagrams

Section 270—Hydraulics Operation, Test, and Adjustments Group 05A—General References Group 10—Calibrations, Preliminary Checks and Operational Checks Group 20—Theory of Operation Group 30—Schematics Group 40—Component and Connector Information Group 50—Tests and Adjustments

Section 290—Cab/Open Operators Station Operation, Test, and Adjustments

Section 240C—Electrical Components and Connectors Group 05—General References Group 40AA—Starting and Charging (SE1) Group 40BA—Lighting—Without License Light (SE2A) Group 40BB—Lighting—With License Light (SE2B) Group 40BC—Brake Switch, Cab Relay, Horn, And Rear Trailer Connector (SE2C) Group 40CA—Instrument Cluster Control (ICC) (SE3) Group 40DA—Kits (SE4) Group 40ZA—Fuses and Relays Group 40ZB—Ground Points Group 40ZC—Interconnects Group 40ZD—Electrical Harness Component Location

Group 05A—General References Group 20B—Seat Theory of Operation Group 30A—Schematics Group 40—Component and Connector Information

Section 299—Service Tools Group 05A—General References Group 05C—Dealer Fabricated and Service Tools

Section 240D—Electrical Tests and Adjustments Group 05—General References Group 50—Tests and Adjustments

Section 250—Drive Systems and Transmission Operation, Test, and Adjustments Group 05A—General References Group 10A—Calibrations, Preliminary Checks and Operational Checks Group 20A—Theory of Operation Group 30A—Schematics Group 40A—Component and Connector Information Group 50A—Tests and Adjustments

Section 260—Steering and Brakes Operation, Test, and Adjustments Group 05A—General References Group 10A—Calibrations, Preliminary Checks and Operational Checks—Steering Group 10B—Calibrations, Preliminary Checks and Operational Checks—Brakes Group 20A—Theory of Operation—Steering Group 20B—Theory of Operation—Brakes Group 30A—Schematics—Steering Group 40A—Component and Connector Information—Steering Group 40B—Component and Connector Information—Brakes Group 50A—Tests and Adjustments—Steering Group 50B—Tests and Adjustments—Brakes

TM149119 (22JUN17)

ii

073117

PN=2

Contents

Section 10 General Information

Page Page

Group 05A—Safety Work In Ventilated Area...............................10-05A-1 Recognize Safety Information .....................10-05A-1 Avoid Backover Accidents ...........................10-05A-1 Prevent Machine Runaway..........................10-05A-2 Avoid Contact with Agricultural Chemicals................................................10-05A-2 Clean Vehicle of Hazardous Pesticides ................................................10-05A-2 Use a Safety Chain......................................10-05A-3 Work in Clean Area .....................................10-05A-3 Decommissioning — Proper Recycling and Disposal of Fluids and Components .....................................10-05A-4 Avoid Harmful Asbestos Dust......................10-05A-4 Avoid Hot Exhaust .......................................10-05A-5 Clean Exhaust Filter Safely .........................10-05A-6 Handle Fuel Safely—Avoid Fires.................10-05A-7 Prepare for Emergencies.............................10-05A-7 Handle Fluids Safely—Avoid Fires.........................................................10-05A-7 Avoid High-Pressure Fluids .........................10-05A-8 Install All Guards .........................................10-05A-8 Use Proper Lifting Equipment......................10-05A-8 Illuminate Work Area Safely ........................10-05A-9 Live With Safety...........................................10-05A-9 Service Machines Safely .............................10-05A-9 Support Machine Properly .........................10-05A-10 Remove Paint Before Welding or Heating ..................................................10-05A-10 Park Machine Safely..................................10-05A-10 Stay Clear of Rotating Drivelines............... 10-05A-11 Follow Safety Instructions.......................... 10-05A-11 Use Proper Tools .......................................10-05A-12 Service Tires Safely...................................10-05A-12 Keep ROPS Installed Properly ..................10-05A-13 Construct Dealer-Made Tools Safely.....................................................10-05A-13 Practice Safe Maintenance........................10-05A-14 Understand Signal Words..........................10-05A-14 Replace Safety Signs ................................10-05A-15 Avoid Heating Near Pressurized Fluid Lines .............................................10-05A-15 Wear Protective Clothing...........................10-05A-15 Service Accumulator Systems Safely.....................................................10-05A-16 Handling Batteries Safely ..........................10-05A-17 Handle Agricultural Chemicals Safely.....................................................10-05A-18 Service Cooling System Safely .................10-05A-18 Use Steps and Handholds Correctly ................................................10-05A-19 Transport Tractor Safely ............................10-05A-19

TM149119 (22JUN17)

Group 05B—General References Deliver Safely ..............................................10-05B-1 Information Available in Sections, Groups and Subgroups ...........................10-05B-2 Glossary of Terms........................................10-05B-3 Trademarks .................................................10-05B-5 Group 05C—Technical Specific References Unified Inch Bolt and Screw Torque Values ..................................................... 10-05C-1 Metric Bolt and Screw Torque Values ..................................................... 10-05C-2 Metric Cap Screw Torque Values—Grade 7 .................................... 10-05C-2 Gasket Sealant Application ........................ 10-05C-3 Service Recommendations for O-Ring Boss Fittings............................... 10-05C-3 Service Recommendations for Flat Face O-Ring Seal Fittings ...................... 10-05C-5 Group 05D—Fuel and Lubricants Diesel Fuel.................................................. 10-05D-1 Handling and Storing Diesel Fuel ............... 10-05D-2 Engine Oil ................................................... 10-05D-2 Alternative and Synthetic Lubricants ............................................... 10-05D-2 Lubricant Storage ....................................... 10-05D-3 Mixing of Lubricants.................................... 10-05D-3 Grease........................................................ 10-05D-3 Transmission and Hydraulic Oil .................. 10-05D-4 Diesel Engine Coolant ................................ 10-05D-5 Group 05E—Serial Number Locations Serial Numbers............................................10-05E-1 Machine Product Identification Number....................................................10-05E-1 Engine Serial Number .................................10-05E-1 Transmission Serial Number .......................10-05E-1

10-1

073117

PN=1

Contents

TM149119 (22JUN17)

10-2

073117

PN=2

Group 05A

Safety Work In Ventilated Area

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

TS220 —UN—15APR13

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.

WS68074,0001AD3 -19-29NOV16-1/1

Recognize Safety Information

Follow recommended precautions and safe operating practices.

T81389 —UN—28JUN13

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.

WS68074,0001AD4 -19-29NOV16-1/1

Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use a signal person when backing if view is obstructed or when in close quarters.

Do not rely on a camera to determine if personnel or obstacles are behind the machine. The system can be limited by many factors including maintenance practices, environmental conditions, and operating range.

PC10857XW —UN—15APR13

Avoid Backover Accidents

WS68074,0001AD5 -19-29NOV16-1/1

TM149119 (22JUN17)

10-05A-1

073117

PN=7

Safety

Prevent Machine 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.

TS177 —UN—11JAN89

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

WS68074,0001AD6 -19-29NOV16-1/1

Avoid Contact with Agricultural Chemicals CAUTION: This enclosed cab does not protect against inhaling vapor, aerosol or dust.

TS220 —UN—15APR13

1. When operating in an environment where pesticides are present, wear a long-sleeved shirt, long-legged pants, shoes, and socks.

2. If pesticide use instructions require respiratory protection, wear an appropriate respirator inside the cab.

3. Wear personal protective equipment as required by the pesticide use instructions when leaving the enclosed cab:

• into a treated area • to work with contaminated application equipment

TS272 —UN—23AUG88

such as nozzles which must be cleaned, changed or redirected • to become involved with mixing and loading activities

4. Before re-entering the cab, remove protective equipment and store either outside the cab in a closed box or some other type of sealable container or inside the cab in a pesticide resistant container, such as a plastic bag.

5. Clean your shoes or boots to remove soil or other contaminated particles prior to entering the cab.

WS68074,0001AD7 -19-29NOV16-1/1

Clean Vehicle of Hazardous Pesticides CAUTION: During application of hazardous pesticides, pesticide residue can build up on the inside or outside of the vehicle.

Clean vehicle according to use instructions of hazardous pesticides.

When exposed to hazardous pesticides, clean exterior and interior of vehicle daily to keep free of the accumulation of visible dirt and contamination.

1. Sweep or vacuum the floor of cab.

2. Clean headliners and inside cowlings of cab.

3. Wash entire exterior of vehicle.

4. Dispose of any wash water with hazardous concentrations of active or non-active ingredients according to published regulations or directives.

WS68074,0001AD8 -19-29NOV16-1/1

TM149119 (22JUN17)

10-05A-2

073117

PN=8

Safety

Use a Safety Chain

Using the appropriate adapter parts, attach the chain to the tractor drawbar support or other specified anchor location.

Provide only enough slack in the chain to permit turning.

See your John Deere dealer for a chain with a strength rating equal to or greater than the gross weight of the towed machine. Do not use safety chain for towing.

TS217 —UN—23AUG88

A safety chain will help control drawn equipment should it accidentally separate from the drawbar.

WS68074,0001AD9 -19-29NOV16-1/1

Work in Clean Area

• 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.

T6642EJ —UN—18OCT88

Before starting a job:

WS68074,0001ADA -19-29NOV16-1/1

TM149119 (22JUN17)

10-05A-3

073117

PN=9

Safety

Decommissioning — Proper Recycling and Disposal of Fluids and Components

TS1133 —UN—15APR13

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

• Use appropriate tools and personal protective

equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials.

• Follow instructions for specialized components.

• Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.

• Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately.

• Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers.

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

• Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);

filters; batteries; and, other substances or parts.

Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes.

• Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.

• Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely.

• Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.

WS68074,0001ADB -19-29NOV16-1/1

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

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.

TS220 —UN—15APR13

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.

Keep bystanders away from the area.

WS68074,0001ADC -19-29NOV16-1/1

TM149119 (22JUN17)

10-05A-4

073117

PN=10