Complete Repair Service Technical Manual for John Deere 8120T, 8220T, 8320T, 8420T & 8520T Tracks Tractors, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere Tracks Tractors 8120T, 8220T, 8320T, 8420T & 8520T workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm1971 - John Deere 8120T, 8220T, 8320T, 8420T and 8520T Tractors Repair Technical Manual.pdf
tm2794 - John Deere Riparazione trattori 8120T, 8220T, 8320T, 8420T e 8520T.pdf

Total Pages: 1,214 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Category: Repair
Language: English Italian
Published on 2018/06/12

MAIN SECTIONS
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General Information
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel and Cooling Systems
      Diesel Fuel System
      Air Intake System
      Engine Cooling System
      Coolers and Air Conditioning Condenser
   Electrical
      Connectors
      Wiring Harness Routings
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring Systems and Sensors
      Armrest Control
      Implement and Accessory Connectors
      Convenience and Accessory Components
   Transmission
      Component Removal and Installation
      In-Tractor Repair
      Transmission
   Drive Systems
      Component Removal and Installation
      Rear Axle Assembly
      Outboard Planetary Final Drive
      PTO
      Steering Gears
      Mid-Frame Drive Shafts
   Steering and Brakes
      Component Removal and Installation
      Steering Column
      Steering Wheel Position Input Assembly
      Steering Pump
      Steering Motor
      Brake Valve
      Brake Components
   Hydraulics
      Component Removal and Installation
      Hydraulic System Repair and Cleanup
      Tandem Hydraulic Pump (Transmission Control-Charge)
      Secondary Hydraulic Pump (Hitch-SCV)
      Hydraulic Filter Bypass
      Hitch Valve, Selective Control Valves, and Couplers
      Hitch
   Miscellaneous
      Hood
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Air Suspension Seat
      Armrest
      Cab Door and Windshield
   Track Frame and Components
      Tracks
      Tension Cylinder and Accumulator
      Track Frame
   Dealer Fabricated Tools
      Fabricated Tools

Table of Contents
Foreword
Dealer Predelivery Information Form
Section 10: General Information
Group 05: Safety
Recognize Safety Information
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Handle Chemical Products Safely
Avoid High-Pressure Fluids
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Avoid Harmful Asbestos Dust
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Construct Dealer-Made Tools Safely
Dispose of Waste Properly
Live With Safety
Group 10: General Information
General Specifications
Overall Dimensions
Sealants and Adhesives Cross-Reference Chart
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Glossary of Terms
Section 20: Engine
Group 00: Component Removal and Installation
Essential or Recommended Tools
Specifications
Remove Engine
Install Engine
Remove Front Frame
Install Front Frame
Group 05: Engine Repair
Engine Repair—Use CTM86 or CTM255
Section 30: Fuel and Cooling Systems
Group 05: Diesel Fuel System
Remove and Install Fuel Fill Tank
Remove and Install Main Fuel Tank
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System
Group 10: Air Intake System
Specifications
Other Material
Service Air Intake System
Repair Aspirator
Group 15: Engine Cooling System
Essential or Recommended Tools
Specifications
Test Radiator and Coolant Tank Cap
Remove and Install Radiator/Aftercooler
Auxiliary Drive Belt Routing
Inspect Tensioner
Repair Variable Fan Drive Assembly
Remove and Install Vistronic Fan Drive—8520T
Group 20: Coolers and Air Conditioning Condenser
Essential or Recommended Tools
Specifications
Other Material
Remove Air Conditioning Condenser
Install Air Conditioning Condenser/Fuel Cooler
Replace Hydraulic Oil Cooler
Leak Test Hydraulic Oil Cooler
Section 40: Electrical
Group 05: Connectors
Essential or Recommended Tools
Other Material
Use Electrical Insulating Compound
Using High-Pressure Washers
Repair AMP Connector
Remove Connector Body from Blade Terminals
Repair CINCH Connectors
Repair CPC CPC is a trademark of AMP Incorporated Blade Type Connectors
Repair CPC CPC is a trademark of AMP Incorporated , Large MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated and METRIMATE METRIMATE is a trademark of AMP Incorporated Pin Type Connectors
Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company Connectors
Repair Small MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated Socket Connector
Repair Small MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorporated Pin Connector
Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors
Repair (Push Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors
Repair SUMITOMO™ Connectors
Repair Weather Pack Weather Pack is a trademark of Packard Electric Connector
Repair YAZAKI™ Connectors
Group 10: Wiring Harness Routings
Wire Number and Color Codes
Ground Point Locations
#1 Cab Ground (Roof)
#2 Cab Ground (Floor)
# 3 Chassis (Single Point Ground)
Miscellaneous Grounds
Main Chassis Harness Routing and Component Identification
Cab Harness Routing and Component Identification—North American
Cab Harness Routing and Component Identification—European
Transmission Harness Routing and Component Identification
Pump Drive Housing Harness Routing
Roof Harness Routing and Component Identification
Remote Mirror Harness Routing and Component Identification
GREENSTAR GREENSTAR is a trademark of Deere & Company Harness Routing and Component Identification
Battery Cable Routing
Starter and Alternator Power Cable Routing
Group 15: Charging Circuit
Repair Alternator—Use CTM77
Disconnect Electrical Circuit
Exploded View—Alternator
Replace Alternator
Group 20: Starting Circuit
Essential or Recommended Tools
Specifications
Repair Starter—Use CTM
Disconnect Electrical Circuit
Remove and Install Starter Motor
Replace Fusible Link
Replace Starter Circuit Relay
Replace Neutral Start Switch
Group 25: Relays, Fuses, Solenoids, and Switches
Essential or Recommended Tools
Other Material
Specifications
General Repair Procedures—Solenoids
Disconnect Electrical Circuit
Load Center Fuses—North America
Load Center Fuses—European
Load Center Relays and Diodes—North America
Load Center Relays and Diodes—European
Replace Starting Aid Solenoid
Replace Electro-Hydraulic Shift Valve Solenoids
Replace Park Brake Release Solenoid
Replace PTO Electro-Hydraulic Valve
Replace SCV Solenoids
Replace Hitch Valve Solenoids
Replace Engine Oil Pressure Switch
Replace Air Filter Restriction Switch
Replace Transmission Manifold Electrical Switches
Exploded View—Right Console Controls and Switches
Replace Right Console Switches
Replace Dome Light Switch
Replace Cab Door Light Switch
Replace Beacon Light Switch
Replace Starting Aid and Ignition Switch
Replace Seat Raise/Lower Switch
Replace Operator Presence Seat Switch
Replace Brake Light Switch
Replace Hand Brake Switch and Potentiometer—European
Replace Hydraulic Clean-Oil Reservoir Level Switch
Replace External Hitch Raise/Lower Switches
Replace A/C High- and Low-Pressure Switch
Replace A/C Deicing Switch and Blower Motor Resistor
Group 30: Monitoring Systems and Sensors
Essential or Recommended Tools
Other Material
Specifications
Disconnect Electrical Circuit
Replace Instrument Control Unit and SCV Set-up Panel
Replace Bulbs in Instrument Control Unit (ICU)
Replace Bulbs SCV Set-Up Panel (SUP)
Replace Corner Post Display and Bulbs
Replace Steering Column Module Bulbs
Replace Steering Column Module
Control Units and Component Identification
Replace Control Units
Replace EEPROM EEPROM—Electrically Erasable Programmable Read-Only Memory In Control Units
Remove EEPROM
Install Replacement EEPROM
Replace Engine Coolant Temperature Sensor
Replace Engine Crank Speed Sensor
Replace Fuel Level Sensor
Replace Fuel Temperature Sensor
Replace Air Intake Temperature Sensor
Replace Foot Throttle Sensor
Replace Track Tension Pressure Sensor
Replace Wheel Speed Sensor
Replace Radar Speed Sensor
Replace PTO Speed Sensor
Replace Steering Motor Speed Sensor
Replace Steering Filter Oil Restriction Sensor
Replace Hydraulic Oil Filter Restriction Sensor and Temperature Sensor
Replace Hitch Position Sensor
Replace Draft Sensing Sensor
CLIMATRAK CLIMATRAK is a trademark of Deere & Company Wire Harness and Component Identification
Replace Outlet Duct Temperature Sensor
Replace Cab Temperature Sensor
Replace Fresh Air Temperature Sensor
Replace Evaporator Temperature Sensor
Group 35: Armrest Control
Disconnect Electrical Circuit
Armrest Test Procedures
Replace Armrest Control Assembly
Replace Armrest Control Unit (ACU)
Exploded View—Armrest Control
Replace Armrest Controls
Exploded View—Engine Speed Control
Exploded View—Transmission Control
Exploded View—SCV Control Lever
Replace Hitch Control
Group 40: Implement and Accessory Connectors
Replace Seven-Terminal Outlet Socket
Replace GREENSTAR GREENSTAR is a trademark of Deere & Company Terminal Connector
Replace Three-Pin Accessory Outlets
Diagnostic/Program Connector
Replace and Adjust Field Lights
Group 45: Convenience and Accessory Components
Replace Circulation Blower Motor
Replace Heating, Ventilation, and Air Conditioning (HVAC) Pressurizer Blower Motor
Replace Seat Air Compressor Motor
Replace Wiper Motors
Replace Windshield Washer Pumps
Replace Hydraulic Charge Pump Auxiliary Heater
Replace Transmission Auxiliary Heater
Remove Radio and Speakers
Section 50: Transmission
Group 00: Component Removal and Installation
Essential or Recommended Tools
Other Material
Specifications
Remove Transmission
Install Transmission
Remove Scavenge Pump
Install Scavenge Pump
Remove Ground-Driven Pump
Install Ground-Driven Pump
Group 05: In-Tractor Repair
Essential or Recommended Tools
Other Material
Specifications
Disengage Park Brake
Replace Transmission Input Shaft Front Seal
Replace Auxiliary Drive Pulley
Replace Transmission Input Shaft Rear Seal—Transmission in Tractor
Repair Clutch Pedal
Replace Clutch Cable
Replace Clutch Operating Spring
Group 10: Transmission
Essential or Recommended Tools
Other Material
Specifications
Clutch Cover Plate Orientation
General Repair Procedures—Power Shift Transmission
Install Transmission in Repair Stand
Cross-Sectional View—Transmission Assembly
Disassemble Transmission
Exploded View—Manifold Valves
Remove and Install Manifold Valves
Cleaning Procedures—Manifold, Rear Cover, and Valves
Disassemble and Assemble Manifold
Inspect and Clean Electro-Hydraulic Valves
Disassemble and Assemble Manifold
Disassemble and Assemble Transmission Rear Cover
Cross-Sectional View—Transmission Input Shaft
Disassemble Input Shaft
Assemble Input Shaft Gear/Clutch Assemblies
Assemble Input Shaft
Cross-Sectional View—Transmission Countershaft
Disassemble Countershaft
Assemble Countershaft Gear/Clutch Assemblies
Assemble Countershaft Gear/Clutch Assemblies
Assemble Countershaft
Cross-Sectional View—Transmission Output Shaft
Disassemble Output Shaft Assembly
Disassemble, Inspect, and Assemble Planetary Carrier
Inspect Clutch Disks
Assemble Output Shaft Assembly
Assemble Transmission
Remove Transmission From Repair Stand
Section 56: Drive Systems
Group 00: Component Removal and Installation
Essential or Recommended Tools
Other Material
Specifications
Remove Rear Axle Assembly
Install Rear Axle Assembly
Remove Outboard Planetary Final Drive Assembly
Install Outboard Planetary Final Drive Assembly
Group 05: Rear Axle Assembly
Essential or Recommended Tools
Other Material
Specifications
Remove Input Gears
Disassemble and Assemble Input Shaft/Gear Assembly
Disassemble and Assemble Pump Drive Gear
Install Pump Drive Housing Oil Baffle Screen
Install Input Gears
Cross-Sectional View—Input Shaft
Adjust Input Shaft Bearing Preload
Remove and Install Pump Drive Housing
Cross-Sectional View—Spiral Bevel Pinion Shaft
Disassemble and Recondition Spiral Bevel Pinion Shaft
Determine Spiral Bevel Pinion Shaft Cone Point Shim Pack
Assemble and Install Spiral Bevel Pinion Shaft
Cross-Sectional View—Spiral Bevel Ring Gear Assembly
Remove and Recondition Spiral Bevel Ring Gear Assembly
Install Spiral Bevel Ring Gear Assembly
Side Quill Adjustment Information
Adjust Carrier Assembly Bearing Preload
Adjust Spiral Bevel Ring Gear Backlash
Group 10: Outboard Planetary Final Drive
Essential or Recommended Tools
Other Material
Specifications
Cross-Sectional View—Final Drive Outboard Planetary Carrier
Remove Outboard Planetary Carrier
Recondition Outboard Planetary Carrier
Cross-Sectional View—Standard and Narrow Tread Housing Assembly
Cross-Sectional View—Wide Tread Housing Assembly
Recondition Axle Housing Assembly
Establish Axle Bearing Preload
Assemble Axle Housing
Group 15: PTO
Essential or Recommended Tools
Other Material
Specifications
Cross-Sectional View—PTO Assembly
Remove PTO Clutch
Cross-Sectional View—PTO Clutch Assembly
Recondition PTO Clutch
Install PTO Clutch
Remove and Install PTO Output Housing Assembly
Cross-Sectional View—PTO Output Housing Assembly
Recondition PTO Output Housing
Remove PTO Clutch Valve
Group 20: Steering Gears
Essential or Recommended Tools
Other Material
Specifications
Remove Steering Planetary, Ring Gear, and Sun Gear
Recondition Steering Planetary
Install Steering Planetary, Ring Gear, and Sun Gear
Remove, Recondition, and Install Steering Idler Gears
Remove, Recondition, and Install Steering Motor Output Gear
Remove, Recondition, and Install Cross Shaft Gear Assembly
Group 25: Mid-Frame Drive Shafts
Essential or Recommended Tools
Specifications
Cross-Sectional View—Mid-Frame Drive Shafts
Remove and Install Drive Shafts
Section 60: Steering and Brakes
Group 00: Component Removal and Installation
Essential or Recommended Tools
Specifications
Install Hydraulic Fittings
Remove and Install Steering Pump
Remove and Install Steering Motor
Flush Steering System
Group 05: Steering Column
Specifications
Repair Steering Column
Group 10: Steering Wheel Position Input Assembly
Specifications
Remove and Install Steering Wheel Position Input Assembly
Repair Steering Wheel Position Input Assembly
Group 15: Steering Pump
Essential or Recommended Tools
Service Parts Kits
Specifications
Exploded View—Steering Charge Pump and Pump Control
Disassemble, Inspect, and Assemble Steering Charge Pump
Disassemble, Inspect, Assemble Displacement Control Valve
Exploded View—Steering Pump
Disassemble, Inspect, and Assemble Hydraulic Steering Pump
Group 20: Steering Motor
Essential or Recommended Tools
Service Parts Kits
Specifications
Exploded View—Steering Motor
Disassemble, Inspect, and Assemble Steering Motor
Group 25: Brake Valve
Service Parts Kits
Specifications
General Repair Procedures—Brake Valve
Remove and Install Brake Valve
Disassemble, Inspect, and Assemble Brake Valve
Adjust Brake Pedal
Adjust Secondary Brake
Bleed Brakes
Check Manual Brakes
Group 30: Brake Components
Specifications
Remove, Inspect, and Install Brake Components
Section 70: Hydraulics
Group 00: Component Removal and Installation
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Tandem Pump
Remove and Install Secondary Pump
Remove and Install Hitch-SCV Valve Stack
Group 05: Hydraulic System Repair and Cleanup
Essential or Recommended Tools
Specifications
Other Material
General Repair Procedures—Hydraulic Systems
Install Hydraulic Fittings
Drain Hydraulic System
Prelubricate, Fill, and Startup Hydraulic System
Conditions Requiring Hydraulic System Cleanup
Hydraulic Cleanup Procedure
Group 10: Tandem Hydraulic Pump (Transmission Control-Charge)
Replace Shaft Seal
Group 15: Secondary Hydraulic Pump (Hitch-SCV)
Essential or Recommended Tools
Specifications
Other Material
Service Parts Kits
Pump Identification
Replace Shaft Seal—45 cm3 Pump
Service Hydraulic Pump Control—45 cm3 Pump
Repair Hydraulic Pump—45 cm3 Pump
Service Hydraulic Pump Control—57 cm3 Pump
Exploded View—57 cm3 Pump
Replace Pump Shaft Seal—57 cm3 Pump
Disassemble and Inspect Pump—57 cm3 Pump
Assemble Hydraulic Pump—57 cm3 Pump
Group 20: Hydraulic Filter Bypass
Service Parts Kits
Specifications
Remove, Inspect, and Install Hydraulic Filter Housing
Group 25: Hitch Valve, Selective Control Valves, and Couplers
Essential or Recommended Tools
Specifications
Disassemble and Assemble Hitch-SCV Valve Stack
Disassemble, Inspect, and Assemble Hitch Valve
Test High Pressure Relief Valve
Disassemble, Inspect, and Assemble Selective Control Valve
Repair SCV Couplers
Group 30: Hitch
Essential Tools
Other Material
Specifications
Remove and Install Lift Cylinder
Cross-Sectional and Exploded View—Hitch Lift Cylinder
Disassemble, Inspect, and Assemble Lift Cylinder
Replace Rockshaft Bushings
Repair Draft Sensing
Section 80: Miscellaneous
Group 05: Hood
Position Hood Forward
Remove and Install Hood
Section 90: Operator Station
Group 00: Component Removal and Installation
Essential or Recommended Tools
Specifications
Remove Cab
Install Cab
Group 05: Heating, Ventilating, and Air Conditioning (HVAC)
Heater Line Routing
Remove HVAC Module
Install HVAC Module
Remove and Install Heater Core
Remove and Install Heater Control Valve (Without CLIMATRAK ClimaTrak is a trademark of Deere & Company )
Remove, Test, and Install Heater Control Valve (With ClimaTrak ClimaTrak is a trademark of Deere & Company )
Leak Test Heater Control Valve
Install Heater Control Valve
Remove and Install Control Cable
Adjust Heating/Cooling Controls
Group 10: Air Conditioning System
Essential or Recommended Tools
Other Material
Specifications
Service Parts Kits
Hose and Tubing O-Ring Connection Torques
Diagram—Air Conditioning System
Reference Chart—Fittings—Air Conditioning System
Leak Test With Dye
Discharge Air Conditioning System
Flushing, Purging, and Evacuating Information
Flush Air Conditioning System
Purge Air Conditioning System
Evacuate Air Conditioning System
Charge Air Conditioning System
Refrigerant Oil Information
Check Compressor Oil Charge
Determine Correct Refrigerant Oil Charge
Add Refrigerant Oil to System
Add Refrigerant Oil to Pressurized System
Remove and Install Compressor
Test Volumetric Efficiency
Test Shaft Seal Leakage
Disassemble and Assemble Compressor Clutch
Check Clutch Hub Clearance
Inspect Compressor Manifold
Disassemble, Inspect, and Assemble Compressor
Remove and Install Compressor Relief Valve
Replace Receiver-Dryer
Remove and Install Expansion Valve
Remove Air Conditioning Condenser
Leak Test Condenser
Leak Test Evaporator
Remove and Install Evaporator
Group 15: Air Suspension Seat
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Seat
Repair Air System
Repair Suspension
Repair Seat Back
Repair Control Knobs
Group 25: Armrest
Remove and Install Armrest Control
Disassemble and Assemble Armrest Adjustment Assembly
Group 30: Cab Door and Windshield
Specifications
Repair Cab Door Latch
Cab Door Adjustment—Step 1
Cab Door Adjustment—Step 2
Cab Door Adjustment—Step 3
Cab Door Adjustment—Step 4
Cab Door Adjustment—Step 5
Replace Windshield Glass or Seal
Section 95: Track Frame and Components
Group 05: Tracks
Essential or Recommended Tools
Specifications
Detension and Tension the Track
Track Alignment
Adjust Track Tread Settings
Remove and Install Track
Group 10: Tension Cylinder and Accumulator
Essential or Recommended Tools
Other Material
Service Parts Kits
Specifications
Remove and Install Track Tension Cylinder
Cross-Sectional and Exploded View—Track Tension Cylinder
Disassemble, Inspect, and Assemble Track Tension Cylinder
Precharge Tension Accumulator
Group 15: Track Frame
Essential or Recommended Tools
Other Material
Specifications
Exploded View—Axle Brace (Wide Axle)
Remove and Install Axle Brace (Wide Axle)
Replace Tension Link Bushings
Remove, Recondition, and Install Front Idler Hub
Remove, Recondition, and Install One Piece Mid-Roller Assembly
Remove, Repair, and Install Two Piece Mid-Roller Assembly
Section 99: Dealer Fabricated Tools
Group 05: Fabricated Tools
Fabricated Tools
DFRW2—Needle Valve Test Hose Assembly
DFRW7—Differential Lifting Tool
DFRW20—Compressor Holding Fixture
DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
DFRW89—Transmission Shaft and Clutch Holding Fixture Tool may be purchased. Order JT07203
DFRW90—Transmission Support Plate
DFRW91—Guide Pins
DFRW92—Mounting Guide Pins
DFRW93—Auxiliary Drive Support Bracket Tool may be purchased. Order JDG860
DFRW97—Transmission Countershaft Rotation Screw
DFRW111—Flushing Wand Tool may be purchased. Order JT03501
DFRW112—Transmission Flushing Shift Valves
DFRW117—Transmission-Hydraulic Flusher
DFRW123—Steering Motor Bypass Hose
DFRW129—STEERING MOTOR SENSOR GAUGE
DFRW136—STEERING PUMP REMOVAL TOOL
DFRW139—Thermal Expansion Valve Replacement Tool
DFRW144—European Narrow Rear Axle Lift Tool
DFRW150—SCV-Hitch Valve Stack Lifting Bracket
DFRW151—Radiator Cap Adapter
DFRW159—Auxiliary Drive Holding Bracket
DFRW173—Mid-Roller Mounting Bracket

John Deere Tracks Tractors 8120T, 8220T, 8320T, 8420T, 8520T Repair Service Manual (TM1971)