John Deere 4120 4320 4520 4720 Compact Utility Tractor Workshop Repair Service Manual TM2137 PDF - MJODTM2137.zip

Complete technical guide featuring electrical wiring schematics for John Deere Compact Utility Tractors — Models 4120 (SN.120101-610000), 4320 (SN. 130101-620000), 4520 (SN. 150101-650000), and 4720 (SN. 170101-670000) (without Cab) — containing every piece of service data needed to service, troubleshoot, and overhaul these machines the way expert technicians do.

This John Deere Compact Utility Tractors 4120, 4320, 4520, 4720 without Cab workshop diagnosis operation tests repair service manual contains:

* 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.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* 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.

tm2137 - Compact Utility Tractors 4120 PIN (120101-610000), 4320 PIN (130101-620000), 4520 PIN (150101-650000), 4720 PIN (170101-670000) (Without Cab).pdf

tm2137 - Compact Utility Tractors 4120 PIN (120101-610000), 4320 PIN (130101-620000), 4520 PIN (150101-650000), 4720 PIN (170101-670000) (Without Cab).epub

Total Pages: 1,710 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

MAIN SECTIONS

Manual Description

Safety

Specifications & Information

Engine - Diesel

Electrical

Electrical - European

Power Train - PRT

Power Train - Hydrostatic

Power Train - Final Drive

Hydraulics

Steering

Brakes

Miscellaneous

tm2137 - Compact Utility Tractors 4120 PIN (120101-610000), 4320 PIN (130101-620000), 4520 PIN (150101-650000), 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

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

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

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

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

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

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

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

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

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