830, 930, 1030, 1130 and 1630
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1 John Deere MODEL: 830, 930, 1030, 1130 and 1630 THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. JD-S-TM4341
2 830, 930, 1 030, 1130 and 1630 Tractors TECHNICAL MANUAL 830,930, 1030, 1130 and 1630 Tractors TM4341 (01 NOV78) English John Deere Werke Mannheim TM4341. (01 NOV78) LITHO IN U.S.A. ENGLISH
3 SECTION 10 - GENERAL Group 5 - Specifications Group 10 - Pre-delivery, delivery and after-sales inspections Group 15 - Lubrication and periodic service Group 20 - Engine and tractor tune-up Group 25 - Tractor separation 830, 930, 1030, 1130 and 1630 Tractors CONTENTS SECTION 20 - ENGINE Group 5 - General information, diagnosing malfunctions Group 10 - Cylinder head and camshaft Group 15 - Cylinder blbck, liners, pistons and connecting rods Group 20 - Crankshaft, main bearings and flywheel Group 25 - Timing gear train Group 30 - Oil pump, oil pressure regulating valve, oil cooler and oil filter Group 35 - Engine cooling system Group 40 - Speed control linkage SECTION 30 - FUEL SYSTEM Group 5 - Diagnosing malfunctions Group 10 - Fuel tank, water trap, transfer pump, fuel filter and air cleaner Group 15 - ROTO DIESEL fuel injection pump Group 20 - Fuel injection nozzles Group 25 - Cold weather starting aids SECTION 40 - ELECTRICAL SYSTEM Group 5 - Diagnosing malfunctions Group 10 - "Bilux" lighting system Group 11 - "Bilux" lighting system (tractors with operator's cab) Group 15 - Sealed-beam lighting system Group 20 - Starting motor Group 25 - Alternator and regulator SECTION 50 - POWER TRAIN Group 5 - Engine clutches and clutch linkage Group 10- High-Low shift unit Group 15 - Creeper transmission Group 20 - Collar-shift transmission Group 25 - Differential Group 30 - Final drives G rou p 35 - Independent PTO Group 40 - Continuous-running PTO SECTION 60 - FRONT AXLE, STEERING SYSTEM AND BRAKES Group 5 - Front axle Group 10 - Steering system Group 15 - Hydraulic brakes SECTION 70 - HYDRAULIC SYSTEM Group 5 - General information, diagnosing malfunctions and pressure tests Group 10 - Oil reservoir, filter, valves and oil cooler Group 15 - Hydraulic pump and transmission oil pump Group 20 - Rockshaft Group 25 - Selective control valves (spool type) Group 30 - Selective control valves (poppet valve type) and breakaway coupler Grou'p 35 - Remote cylinder Technical Manual TM-4341 (April-78) SECTION 80 - MISCELLANEOUS Group 5 - Belt pulley Group 10 - Operator's seats Group 15 - Front and rear wheels Group 20 - Roll guard Group 25 - Operator's cab ventilation and heating Group 30 - Operator's cab c Printed in Germany (B 8)
4 830,930,1030,1130 and 1630 Tractors TM4341 (April-78) General 10 Specifications 5-1 Section 10 General GROUP 5 - SPECI FICATIONS Serial numbers Model numbers Engine Electrical system Engine clutch Transmission High-Low shift unit Creeper transmission Differential and final drives Differential lock Power take-off Hydraulic system Power steering Manual steering Hydraulic brakes Handbrake... ::...'5-3 Capacities Travel speeds Front and rear wheels Dimensions and weights GROUP 10 -PREDELIVERY, DELIVERY AND AFTER-SALES INSPECTIONS Predelivery inspection Delivery inspection After-sales inspection GROUP 15 - LUBRICATION AND PERIODIC SERVICE Lubrication and periodic service ROUP 20 - ENGINE AND TRACTOR TUNE-UP General information Preliminary engine testing Engine tune-up Performance test Tractor adjustments Standard torques Special tools GROUP 25 - TRACTOR SEPARATION Separating between engine and tractor -Front end Removing and installing engine Removing and installing clutch housing Removing and installing final drives Removing and installing rockshaft Removing and installing operator's cab Torques for hardware Special tools Printed in Germany (B 8)
5 830,930, 1030, 1130 and 1630 Tractors TM-4341 (Nov-78) General 10 Specifications 5-3 TRANSMISSION Collar shift transmission with helical cut gears. This transmission is available in two variations: 8 speed transmission with parking lock, without independent hand brake; 8 speed transmission without parking lock and with independent hand brake. With this transmission 8 forward and 4 reverse speeds are available. HIGH-LOW SHI FT UNIT Hydraulically controlled reduction gear which can be shifted under load, with "wet" multiple disk clutch and "wet" multiple disk brake. Allows reduction of the individual gear speeds by 21 %. CREEPER TRANSMISSION Mechanically controlled reduction gear. Allows reduction of range I and reverse gear speeds by 77%. DIFFERENTIAL AND FINAL DRIVES Planetary reduction gear and differential with spiral bevel gears. 01 FFERENTIAL LOCK Hand or foot operated; spring-loaded out of engagement. PTO Continuous Running PTO The PTO shafts are independent of the transmission if the tractor is equipped with a dual stage engine clutch. Independent PTO Independent of transmission, can be engaged and. disengaged under load. The independent PTO shaft is engaged by a hydraulically operated disk clutch. Disengaging the clutch is achieved by operating the hydraulically actuated band type brake. PTO Shaft Speeds (in rpm) Engine Speed 540 rpm 1000 rpm rpm shaft shaft HYDRAULIC SYSTEM Closed center, constant pressure system; also includes rockshaft, power steering and selective control valves. Stand-by pressure bar (2250 psi) Pump... 4 or 8-piston pump driven by the engine POWER STEERING The steering system is a "closed center" type incorporated in the hydraulic system and supplied with oil by the tractor hydraulic pump. It is connected to the front wheels by means of a steering linkage. MANUAL STEERING The manual steering is a recirculating ball bearing, worm and nut type. A number of steel balls between ball nut and steering wheel shaft provide for positive engagement of steering wheel and steering linkage. HYDRAULIC BRAKES The disk brakes run in an oil bath and are hydraulically controlled. HANDBRAKE Band-type locking brake acting on differential. CAPACITIES Fuel tank.... Cool ing system.... Engine crankcase i ncl. filter.... without filter.... Transmission-hydraul ic system Dry system.... At service intervals.... Belt pulley.... See Operator's Manual. TRAVE L SPEEDS LitelJ FRONT AND REAR WHEELS U.S. gals For tire sizes, treads, inflation pressure and weights see Operator's Manual. DIMENSIONS AND WEIGHTS See Operator's Manual. Printed in Germany (K 8)
6 10 General 25-4 Tractor S.eparation 830,930, 1030, 1130 and 1630 Tractors TM-4341 (April-78) On tractors equipped with starting fluid aid: Disconnect starting fluid line at intake manifold. On tractors equipped with Th erm os tart aid: Disconnect cable at heater of intake manifold. Remove breather line of hydraulic oil reservoir from clamp at rocker arm cover. Disconnect cables at start safety switch and stop light switch. On tractors with High-Low shift unit, disconnect cable at transmission oil pressure warning switch. Remove batteries and free starter cable. Attach JD and lifting eyes to cylinder head and attach engine to a suitable hoist. Remove cap screws 1 (figs. 4 and 5) and hex. nut 5 (fig. 5) securing flywheel housing to clutch housing. Remove engine by means of the hoist. IMPORTANT: Move engine properly in line with drive shaft and hollow drive shaft until these shafts come free of the clutch disk of the engine dualstage clutch, or free of clutch disk and torsion damper if tractor is equipped with a single-stage clutch. INSTALLATION Fig. 5 - Separting between Engine and Clutch Housing, L.H. Side 1 Cap screw (3 used) 2 Speed control rod 3 Shut-off cable 4 Cap screw (2 used) 5 Hex. nut Disconnect speed control rod 2 (fig. 5) and shutoff cable 3 at fuel injection pump. On tractors with underneath muffler: Remove muffler. On tractors up to serial number L, disconnect temperature gauge sensing bulb from cylinder head. Align engine properly with drive shaft and hollow drive shaft. Move engine towards rear of tractor. Align splines of both shafts with internal splines of clutch disks (tractor with dual-stage clutch), or (if equipped with a single-stage clutch) with splines of clutch disk and torsion damper. Align screw holes of flywheel housing with holes in clutch housing. Slide engine evenly towards clutch housing. Engage two dowels of flywheel housing in bores of clutch housing until engine is in full contact with clutch housing. IMPORTANT: Make sure flywheel housing is flush against clutch housing before tightening cap screws and hex. nut to specified torque. On 1630 tractors only: Secure oil pan to clutch housing, tightening both cap screws to the specified torque. On tractors from serial number L, disconnect cable at temperature gauge sending unit. On tractors without operator's cab, remove left-hand dash panel as well as both batteries. Remove cap screws attaching dasboard to flywheel housing. Printed in Germany (88)
7 830,930, 1030, 1130 and 1630 Tractors TM-4341 (Nov-78) Engine General Information, Diagnosing Malfunctions Section 20 Engine GROUP 5 - GENERAL INFORMATION, DIAGNOSING MALFUNCTIONS General information Diagnosing malfunctions GROUP 10 - CYLINDER HEAD AND CAMSHAFT General information Cyl i nder head Removal Repair Installation Adjusting valve clearance Camshaft Removal Repair Installation Specifications..., Torques for hardware Special tools GROUP 25 - TIMING GEAR TRAIN General information Removal Repair Installation Specifications Torques for hardware Special tools GROUP 30 - ENGINE LUBRICATION SYSTEM General information Removal Repair..., Installation Adjusting engine oij pressure Specifications Torques for hardware Special tools GROUP 15 - CYLINDER BLOCK, LINERS, PISTONS AND CONNECTING RODS General information Removal Repair Assemb Iy Installation Specifications Torques for hardware Engine break-in Tune-up data Special tools GROUP 20 - CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL General information Removal Repair Installation Specifications Torques for hardware Special tools GROUP 35 - COOLI NG SYSTEM General information Diagnosing malfunctions Repair Radiator Adjusting fan belt Water pump Checking thermostat Specifications Torques for hardware Special tools GROUP 40 - SPEED CONTROL LINKAGE General information Removal and disassembly Repair Assembly and installation Adjustment Specifications Printed in Germany (K 8)
8 20 Engine 25-4 Timing G~ar Train 830, 930, 1030, 1130 and 1630 Tractors TM-4341 (April-78) Make sure that the rear thrust washer 1 (fig. 5) is installed. If a new shaft is installed, first drive spring pin 6 (fig. 5) in shaft so that it protrudes from the front face of the shaft by a specified dimension (see Specifications). Install front thrust washer 5 and cap screw 7, secure gears against rotation and tighten screw to the specified torque (see Torques for Hardware). Fig. 4 - Timing I njection Pump Gear, Using Timing Tool No. JD 254 c Timing mark 7. After having timed the camshaft and injection pump gear, carefully slide upper idler gear on shaft, simultaneously engaging the gear in crankshaft, camshaft and injection pump gears with a rotating motion. Use special care not to rotate the gears timed previously. 3 4 Fig.6 - Lower Idler Gear Installed, Sectional View 5 1 Rear thrust washer 2 Front plate 3 Idler gear 4 Idler gear bushing 5 Front thrust washer 6 Spring pin 7 Cap screws 8 Shaft 9 Special steel washer / / '.-'i7ir Install lower idler gear. If a new shaft is installed, drive spring pin 6 (fig. 6) in shaft so that it protrudes from front face of shaft by a specified value. Slide rear thrust washer 1 on shaft journal and spring pin. Drive in shaft until thrust washer is fully seated. Secure shaft with special steel washer 9 and cap screw 7 (see fig. 6). Tighten screw to specified torque (see Torques for Hardware). Fig. 5-1 Rear thrust washer 2 Front plate 3 Idler gear 4 Idler gear bushing Upper Idler Gear Installed, Sectional View 5 Front thrust washer 6 Spring pin 7 Cap screw 8 Shaft Install front thrust washer 5 over the spring pin 6, screwing the second cap screw 7 (see fig. 6) into the shaft. Tighten screw to specified torque (see Torques for Hardware). Printed in Germany (K 7)
9 S30, 930, 1030, 1130 and 1630 Tractors TM4341 (April-7S) Fuel System Diagnosing Malfunctions Section 30 Fuel System GROUP 5 - DIAGNOSING MALFUNCTIONS GROUP 20 - FUEL INJECTION NOZZLES Diagnosing malfunctions GROUP 10 - FUEL TANK, WATER TRAP, TRANSFER PUMP, FUEL FILTER AND AIR CLEANER Fuel tank General information Removal Repair..., Installation Water trap.. " Fuel. transfer pump General information Diagnosing malfunctions Removal... "... " Repai r Installation Fuel filter General information Repair General information Removal Testing and inspection Disassembly Repair..., Assembly (1st stage) Adjustment Assembly (2nd stage) Installation Specifications... ; Torques for hardware Special tools... " GROUP 25 - COLD WEATHER STARTING AIDS Starting fluid aid General information Repair Thermostart aid General information Repair Torques for hardware Dry-type air cleaner General information Repai r Air pre-cleaner General information Repai r GROUP 15 - ROTO DIESEL FUEL INJECTION PUMP General information Removal Repair Installation and adjustment Adjusting fuel delivery to different altitudes S Torques for hardware... : S Printed in Germany (K 7)
10 830, 930, 1030, 1130 and 1630 Tractors TM-~341 (April-78) Electrical System Diagnosing Malfunctions Section 40 Electrical System GROUP 5 - DIAGNOSING MALFUNCTIONS Batteries Alternator Tests and diagnosis on tractor Controls Starting motor Headlights GROUP 10 - "BllUX" LIGHTING SYSTEM Important notes General information System Batteries Controls and instruments Wiring diagram GROUP 11 - "BllUX" LIGHTING SYSTEM (tractors with operator's cab) I mportant notes General information System Batteries Controls and instruments Wiring diagram GROUP 15 - SEALED BEAM LlGHTI NG SYSTEM Important notes General information System Batteries Controls and instruments Cables and wires Wiring diagram GROUP 20 - STARTING MOTOR General information Removal Disassembly Repair Assembly Installation lubrication instructions before and during assembly Specifications Special tools... " GROUP 25 - ALTERNATOR AND REGUlATOR Alternator General information Removal Disassembly Testing and repair Assembly Output test Installation Regulator Specifications Torques for hardware Printed in Germany (K 7)
11 40 Electrical System 20-2 Starting Motor 830,930, 1030, 1130 and 1630 Tractors TM-4341 (April-78) Inspect all parts for wear or damage. ARMATURE Test armature for grounds, using a test lamp with approx. 40 volts a.c. Fig. 3 - Commutator End Frame, Removed Remove engaging lever pivot screw. Carefully remove armature with drive and frame assembly from field frame, taking care not to damage field coils. Withdraw engaging lever and armature as a unit from drive end (see fig. 4). L Fig. 5 - Testing Armature for Grounds Place one test point on a commutator bar and the other test point on iron core of armature. The test lamp should not light up while making this test. If it does light, the armature is grounded and must be replaced. Fig.4 - Removing Engaging Lever and Armature from Drive End Drive back pinion stop ring and open up snap ring. Remove snap ring, pinion stop ring, drive with pinion, center bearing and armature brake parts from armature shaft. REPAIR Wash parts in a safe solvent and dry with compressed air. Armature, windings and drive with pinion must not be placed in cleaning fluid. ls5570 Fig. 6 - Testing Armature for Short Circuit Check armature for short circuit, using a testing device such as Bosch EFAW 90 or 95 as well as growler EFAW 95/10. Often, a shorted winding is indicated by a burned commutator bar. NOTE: See "Fundamentals of Service - Electrical System" manual for details. Printed in Germany (K 7)
12 830,930, 1030, 1130 and 1630 Tractors TM-4~41 (April-78) Power Train 50 Engine Clutches and Clutch Linkage 5-1 Section 50 PO\Ner Train GROUP 5 - ENGINE CLUTCHES AND CLUTCH LINKAGE Diagnosing malfunctions Clutch linkage General information Repair Installation Adjustment Engine dual-stage clutch General information Removal Disassembly Repair Assemb Iy Adjustment... = Installation Adjusting externally Engine single-stage clutch General information Removal Disassembly... ' Repair Assembly Installation Adjustment Specifications Torques for hardware Special tools GROUP 10 - HIGH-LOW SHIFT UNIT General information Checking operating pressure... " 10-4 Diagnosing malfunctions Removal Disassembly Repair Assembly Installation Specifications Torques for hardware Special tools GROUP 15 -CREEPER TRANSMISSION General information Removal Disassembly... " 15-4 Repair Assembly Installation., Specifications Torques for hardware Special tools GROUP 20 - COLLAR-SHIFT TRANSMISSION General information Diagnosing malfunctions Shifter mechanism Transmission shafts and gears..., 20-6 Specifications Torques for hardware GROUP 25 - DIFFERENTIAL General information Diagnosing malfunctions Repair Adjustment Installation Specifications Torques for hardware GROUP 30 - FINAL DRIVES General information Diagnosing malfunctions Removal Repair Adjustment Installation Specifications Torques for hardware GROUP 35 - INDEPENDENT PTO General iniormation Operation Checking operating pressure Diagnosing malfunctions PTO shaft assembly PTO clutch PTO brake Control valve assembly Specifications GROUP 40 - CONTINUOUS-RUNNING PTO General information Single. rear 540 rpm PTO Removal Repair Installation Dual rear 540 and 1000 rpm PTO Removal Repair Installation Rear 540 rpm and mid 1000 rpm PTO Mid PTO Removal...' Repair Installation Specifications Printed in Germany (A 8)
13 830, 930, 1030, 1130 and 1630 Tractors TM-4341 (April-78) Front Axle, Steering System and Brakes Front Axle Section 60 Front Axle, Steering System and Brakes GROUP 5 -; FRONT AXLE GROUP 15 - BRAKES General Information Hydraulic Brakes Removal Diagnosing malfunctions Repair General information Installation and adjustment Removing brake valve Specifications..._ Repair of brake valve Torques for hardware Installing brake valve Adjustment and bleeding Removing pressure rings GROUP 10 - STEERING SYSTEM and brake disks Repair of pressure rings Power Steering and brake disks Operation Installing pressure rings Checking steering system and brake disk Diagnosing malfunctions Removal Hand Brake Repair General information Adjustment of a valve housing assy Removal Assembly Repair Installation and adjustment Installation Adjustment Manual Steering General information Specifications Removal Repair..., Assembly..., Adjustment Installation Specifications Torques for hardware Special tools Printed in Germany (A 8)
14 830,930,1030,1130 and 1630 Tractors TM-4341 (April-78) Hydraulic System General Information, Diagnosing Malfunctions and Tests Section 70 Hydraulic System GROUP 5 - GENERAL INFORMATION, DIAG- NOSING MALFUNCTIONS AND TESTS General information Operation Diagnosing malfunctions Tests Specifications Special tools GROUP L RESERVOI R, FI L TER, VALVES AND 01 L COOLER Main oil reservoir, transmission oil filter and intake screen General information Repair By-pass valve of transmission oil filter General information Repair Surge relief valve in clutch housing General information Repair Check valve in inlet line to hydraulic pump (Tractors without High-Low shift unit and without independent PTO) 10-3 General information Repair Flow control valve of power steeri ng General information Repair Flow control valve for attached implement with hydraulic motor General information Repair Auxiliary oil reservoir General information Repair Oil cooler..., General information Specifications Torques for hardware GROUP 15 - HYDRAULIC PUMP AND TJ3ANSMISSION 01 L PUMP Hydraulic pump General information Operation Repair Adju~t'11ent ~ Transmission 011 pump General information Removal Repair I nstaliation Specifications Printed in Germany (B 8) Torques for hardware Special tools GROUP 20 - ROCKSHAFT General information Repair... ~ Assembly Adjustment Load control mechanism Repair Installation Adjustment Th ree-po i nt hitch Specifications Adjustments Torques for hardware Special tools GROUP 25 - SELECTIVE CONTROL VALVES (SPOOL TYPE) General information Operation Removal Repair I nstaliation Adjustment Specifications Torques for hardware GROUP 30 - SELECTIVE CONTROL VALVE (POPPET VALVE TYPE) _ AND BREAKAWAY COUPLER Selective control valve General information Diagnosing malfunctions Operation Repair Adjustment Breakaway coupler..., General information Repair Specifications Torques for hardware Special tools GROUP 35 - REMOTE CYLINDER General information Repair Bleeding Specifications Torques for hardware,
15 830,930, 1030, 1130 and 1630 Tractors TM-4341 (April-78) Miscellaneous Belt Pulley Section 80 Miscellaneous GROUP 5 - BELT PULLEY General information Removal and disassembly Repa,ir Assembly and adjustment Specifications GROUP 20 - ROLL GUARD 2-Post roll guard Installation Post roll guard Installation Torques for hardware GROUP 10 - OPERATOR'S SEAT De Luxe Seat General information Repair Standard Seat General information Repair... : GROUP 15 - FRONT AND REAR WHEELS Front wheels Standard type Repair Heavy-duty type Repair Adjusting front wheel bearings (both front wheel types) Rear wheels (on tractors with rack-and-pinion axle).., General information Removal Repair Installation Torques for hardware GROUP 25 - OPERATOR'S CAB-VENTILAtiON AND HEATING General information Removal Repair Installation GROUP 30 - OPERATOR'S CAB General information Removal Repair Specifications Torques for hardware Group 5 Belt Pulley GENERAL INFORMATION The belt pulley assembly is driven by the PTO stub shaft at 540 rpm or 1000 rpm respectively. It is a helical gear type unit and is attached to the transmission case. REMOVAL AND DISASSEMBLY Drain oil from pulley case by removing filler plug. Remove pulley guard. Remove pulley from shaft, using a puller if necessary: Printed in Germany (A 8)
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