John Deere 820 Tractor Service Technical Manual.pdf

John Deere °
820
Tractor
TECHNICAL MANUAL
John Deere 820
Tractor
TM4212 (01Jun72) English
John Deere Werke Mannheim
TM4212 (01Jun72)
LITHO IN U.S.A.
ENGLISH

SECTION 10 — GENERAL INFORMATION
Group 5 - Specifications
CONTENTS
Model 20 Tractor
(from tractor serial no. 37000)
Technical Manual
TM-4212 (June-72)
Group 10 - Pre-delivery, delivery and after-sales inspections
Group 15 - Lubrication and periodic service
Group 20 - Engine and tractor tune-up and adjustment
Group 25 - Separation
SECTION 20 — ENGINE
Group S General information, diagnosing malfunctions
Group 10 - Cylinder head and camshaft
Group 15 - Cylinder block, 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 and oil filter
Group 35 - Engine cooling system
Group 40 - Speed control
SECTION 30 — FUEL SYSTEM
Group 5 - Diagnosing malfunctions
Group 10 - Fuel tank, transfer pump, fuel filters
Group 15 - BOSCH injection pump
Group 20 - ROTO DIESEL injection pump
Group 25 - ROOSA MASTER MODEL CB injection pump
Group 30 - ROOSA-MASTER injection nozzles
Group 35 - BOSCH injection nozzles
Group 40 - Cold weather starting aids
SECTIOh 40 — ELECTRICAL SYSTEM
Group 5 - Diagnosing malfunctions
Group 10 - ”BILUX” lighting system
Group 15 - Sealed-beam lighting system (from tractor serial no. 77054 L)
Group 16 - Sealed-beam lighting system (up to tractor serial no. 77053 L)
Group 20 - Starting motor
Group 25 - Alternator and regulator
Group 30 - Generator and regulator
SECTION 50 — POWER TRAIN
Group 5 - Engine dual stage clutch and clutch linkage
Group 10 - Collar-shift transmission
Group 15 - Differential assembly
Group 20 - Final drives
Group 25 - PTO shafts
SECTION 60 — FRONT AXLE, STEERING SYSTEM AND BRAKES
Group S Front axle
Group 10 - Manual and power steering
Group 15 - Brakes
SECTION 70 — HYDRAULIC SYSTEM
Group 5 - General information, diagnosing malfunctions, pressure tests
Group 10 - Oil reservoir, filter and valves
Group 15 - Hydraulic pump and transmission oil pump
Group 20 - Rockshaft
Group 25 - Selective control valve
SECTION 80 — MISCELLANEOUS
Group 5 - Belt pulley
Group 10 - DE LUXE seat
Group 15 - Front wheels

hlodel 820 Tractor
2 TM-4212 (Jan-70)
INTRODUCTION
This technical manual for the 820 tractor is a
concisely written publication for the service
personnel. It contains procedures and specifi-
cations which an individual cannot be expected to
remember.
The table of contents on the first page of this
manual lists the individual sections and their
groups. A table of contents on the first page of
each section lists the groups in the section and the
page number of the major subjects found in each
group. Coloured tabs make it easy to locate the
individual sections.
Coverage for each components includes:
General information, diagnosing malfunctions
checks, removal, disassembly, repair, assembly, in-
stallation, adjustments, specifications and special
tools. Specifications and special tools are always
listed at the end of each group.
The section ”GENERAL INFORMATION”
includes instructions for ”Pre-delivery, delivery and
after-sales inspections” as well as ”Engine and
tractor tune-up” to restore full performance.
Tractor service and lubrication as well as lubricants
required are described in the Operator's Manual.
Little explanation is given about theory of
operation in this manual unless the theory is
peculiar only to the component in this machine.
Basic theory of operation and general information
about the systems or components of the tractor
will be found in the ”JOHN DEERE F,undamen-
tals of Service’ manuals.
Keep this ”Technical Manual” in the shop where it
is readily accessible and refer to it whenever in
doubt about correct procedures of servicing the
820 tractor. Using it as a guide for any and all
service problems will reduce error and costly delay.

Model 820 Tractor
TM-4212 (Jan-70)
General Information lo
Specifications îî-1
Section 10
GENERAL INFOAATION
CONTENTS OF THIS SECTION
GROUP 6 — SPECIFICATIONS
Page
GROUP 15 — LUBRICATION AND
ADJUSTMENT
Serial numbers...................................................5-2
Model numbers......................................5-2
Engine..............................................................................5-2
Engine dual-stage clutch ...... 5-2
Lubrication and adjustment ......
Pege
Electrical systerti .............5-G
2
ROUP 20 — ENGINE AND TRAC'POR
Collar-shift transmission.........................................5-3
Differential and final drives..................................5-3
Dil'lezential lock..........................................................5-3
Powershafts ..................................................................5-3
Hydraulic system.......................................................5-3
Steering system...........................................................5-3
Manual steering . ... 5-
Hydraulic brakes........................................................6-3
TUNE-UP AND AD2USTUÉNT
Generâlinlormation........................................2O-1
Preliminary engine testing . .... 2t›-1
Engine checks and adjustment ... 20-1
Performancetest............................................20-3
Tractor adjustment ........................................20-3
Standard torques ...........................................20-5
Handbrake - . - - . -+- Special tools ..............................................2O-5
Capacities ......................................................................5-3
Travelspeeds .. ..........................5-
Front and rear wheels.............................................5-3
Dimensions and weights.........................................5-3
GROUP 10 — PREDELIVERY, DELIVERY
AND AFTER-SALES INSPEC-
GROUP 25 — SEPARATION
Separating between engine and
tractor front end
R•u•• l and installation of
. 25-1
TIONS
Predelivery inspection ......... 10-1
Delivery inspection . .. . $0-
engïne ........... - .. •- • -+
Removal and installation of
clutch houxing ............. 25-4
Removal and installation of
tïnal drives ............... 25-6
After-sales inspection .....................................1fi-$
Removal a:nd installation of
rockshaft
Tortues for hardware
Special tOols
. 2S 7
25-5

10 General Information
5-2 Specifications
£OUp
SPECIFICATIONS
SERIAL NUMBERS
The engine serial number is stamped into the name
plate at the lower right of the front cylinder block.
NOTE: I f ordering engine parts, indicate all digits
Model 820 Tractor
TM-42 2 70)
1
Engine horsepower on tractors eqnipped u›ith
BOSCH or ROTO DIESEL injection pump.
Flywheel horsepower ) at 2100 rpm
incl. accessories2) ..........................32 HP (32 PS)
without accessories2)...................34 HP (34 PS)
of the serial number on the name plate.
PTO horsepowe,r3, ) , ... 29 HP (29 PS)
The name plate showing the tractor serial number
is located on the right-hand side of the front sup-
port.
NOTE: I{ ordering trac tor parts, (excluding engine
parts), indicate all digits of the serial number on
the name plate.
MODEL NUMBERS
The injection pump, injection nozzles, the genera-
tor, starter and the main hydraulic pump have
model numben to facilitate identification of dif-
ferent makes of a given unit.
SPECIFICATIONS
ENGINE
Number of cylinders . 3
Cylinder liner bore...................................3.86 in (98 mm)
Stroke....................................................... 4.33 in. (110 mm)
Displacement .......152 cu.in. (2490 cm )
Compression ratio ........ 16.7 1
Maximum torque at
(at 2100 rpm engine speed and
647 or 1016 rpm powershaft speed)
Engine horsepower on tractors equipped with
R OO!SA MACTER injection pump
Flywheel horsepower1) at 2100 rpm
incl. accessories2).......................... 34 HP (34 PS)
without accessories2).................. 36 HP (36 PS)
PTO horsepower )......................................31 HP (31 PS)
(at 2100 rpm engine speed and
547 or 1016 rpm powershaft speed)
ENGINE DUAL-STAGE CLUTCH
Dual dry disk clutch, foot-operated.
ELECTRICAL SYSTEM
Batteries . 2xl2 Volts, 60 Ah
Starter................................................12 Volts, 4 HP (4 PS)
Generator .............12 Volts, 11 A
Battery terminal grounded....................................negative
1400 rpm 92 ft.lbs. (12.7 mkg)
firing order .......
Valve clearance (engine hot or cold)
Intake valve 0.014 in. (0.35 mm)
Outlet valve 0.018 in. (0.45 mm)
FatiMe
Slowiae
1-2-8
Z545 rpm
. 650 rpm
1) 1 PS - 1 ch = 0.7B6 KW:1 KW= 1.06 PS = 1.36
ch;1 PS = 0.986 HP;1 HP = 1.01 PS
2) Water pump, fan, generator, air cleaner and
muffler.
3) With the engine run in (above 100 hours of
operation) and having reached operating
Working speed range . 1400 to 2100 rpm temperature (engine and transmission); measured
by means of a dynamometer. Permissible
variation z 5%.

Model 820 Tractor
TM-4212 (Jan-70)
COL LAR-SHIFT TRANSMISSI ON
8-speed transmission with helical-cut gears. This
transmission is available in three variations:
8-speed transmission with parking lock, without
independent hand brake, 8-speed transmission
without parking lock and with independent hand
brake; 8-speed transmission without parking lock,
with blocked 8th gear and independent hand
brake.
With this transmission 8 or 7 forward and 4 reverse
speeds are available.
DI FFE RENTIAL AND FINAL DRIVES
Planetary reduction gear and differential with
spiral bevel gears.
DI FFE RENTIAL LOCK
Hand or foot operated; spring-loaded out of
engagement.
POWERSHA FTS
Single, 540 rpm rear powershaft or dual 540 and
1000 rpm rear powershaft. Conversion from 540
rpm to 1000 rpm and vice •rersa is made by inter-
changing the stub shaft. In addition, a front 1000
rpm powershaft may be installed.
The powershafts are independent of the transmis-
sion as the tractor is equipped with a dual-stage
engine clutch.
General Information 10
Specifications 5-3
HYDRAULIC SYSTEM
Open center, constant oi1 flow system; also
includes rockshaft and selective control valves.
Pump...........................................................................gear pump
driven by the engine
System pressure.........................2000 psi (140 kg/cm2)
STEERING
The 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 hydrau-
lically controlled.
HANDBRAKE
Band-type locking brake acting on differential.
Engine crankcase
Transmission-hydraulic
Pomersha(I Speeds
engine speed 540 rpm
in rpm shaft
1000 rpm
shaft
TRAVEL SPEEDS
See Operator's Manual
FRONT AND REAR WHEELS
For tire sizes, treads, inflation pressure and weights
see Operator's Manual.
DIMENSIONS AND WEIGHTS
See Operator's Ma.nua1.
CAPACITIES !mP. US Lit.
Gals. Gals.
Fuel tank........ 13.75 16.5 62.5
Cooling system.. . 2.3 2.75 10.5
incl. filter . . . .. 1.25 l .5 5.7
system
Dry system..............................6.6 7.9 30.0
At service intervals . 6.l5 7.4 58.0
Oil-bath air cleaner 0.22 0.26 1.0
Belt pulley . . .. 0.25 0.30 l .l
650 169 315
2067 538 1000
2075 540 1004
2100 547 1016
2225 578 1075
2545 662 1232

Model 820 Tractor
TM-4212 (Jan-70)
Predelivery, Delivery and After-Sales Inspections 10-1
Group 10
PREDELIVERY, DELIVERY AND
AFTER-SALES INSPECTIONS
PREDELIVER Y INSPECTION
Every new JOHN DEERE tractor leaves the
factory in such a condition that it can be delivered
to the customer after a minimum of service.
To promote complete customer satisfaction,
proper predelivery service including mending of
possible shipping damage and giving the finishing
touches to the tractor, are of prime importance to
the dealer.
A tag pointing out the factory-recommended
procedure for predelivery service is attached to
each new tractor before it leaves the factory. The
reverse side of this tag is filled in by the factory
after the tractor has undergone a thorough in-
spection prior to shipping.
After completing the factory-recommended dealer
checks and services listed on the predelivery. tag,
remove the tag from the tractor and file it with the
shop order for the job. The tag will then serve as a
basis for certifying that the unit has received the
proper predelivery service.
TEMPORARY TRACTOR STORAGE
S ervice Specifications Reference
Check radiator for coolant loss and
antifreeze protection (gravity of anti-
freeze and rust inhibitor mixture)
Coolant level should be
midway between radiator
core and bottom edge of
filler neck
Operator's manual
CAUTION: On tractors shipped with
dry-charged batteries or without
battéries which are to be started by
means of a slave battery, do not re-
move insulating tape on terminal of
cable to starter under any circumstan-
ces. Also, do not remove — contrary
to earlier statements — wire between
terminals D+ of regulator and D+ of
generator. If this advice is disregarded,
damage to generator and regulator
may result.
Remove batteries, drain and store
electrolyte.
Reduce shipping pressure of tires
Cover tractor and tires for protection
and cleanliness
Store at room temperature
Operator's manual

10-2 Predelivery, Delivery and After-Sales Inspections
Model 820 Tractor
TM-4212 (Jan-70)
BEFOREDELIVERIN€TRACTOR
Service Specifteatloos R e ie r e zs c e
COOLING SYSTEM
Check radiator for coolant loss
Check gravity of antifreeze and rttst
inhibitor mixture
ELECTRICAL SYSTEM
CAUTION: If the tractor is to be
started by means of a slave battery,
do not remove insulating type on
terminal of battery cable to starter
under any circumstances. Also, do
not remove — contrary to earlier
statements — wire between terminals
D+ of regulator and D+ of generator.
If this advice is disregarded, damage
to generator and regulator may result.
If the batteries are to be installed in the
tractor, remove insulating tape on terminal
of battery cable if tractor was shipped
with dry-charged batteries or without
batteries.
Fill batteries with electrolyte, charge
batteries and install in tractor.
TIRES AND WHEELS
Check tire inflation pressure
Retighten wheel bolts
LUBRICA’I'ION
Check crankcase oil level
Check transmission-hydraulic
system oil level
Lubricate all lubrication points
on the tractor
midwax between radiator
filler neck.
Operator's manual
Operator's manual
Section 40, group 10
”Fundamentals of Service,
Electrical Systems” manual
under ”Batteries”
Operator's manual
Operator's manual
’top mark on dip stick Operator's manual
Operator's manual
OperatorsmanuM

Model 820 Tractor
TM-4212 (Jan-70)
Generał Information 10
,Predelivery•, Delivery and After-Salęs Inspections 10-3
BE FORE DELIVERING TRACTOR - Continued
S ervice Specifieations R eference
ENGINE
Check oi1 bath air eleaner Fill with oi1 to ”Fiill”
mark
Check dry type air cleaner Operator's manual
Fill fuel tank and start engine Capacity: 13.75 Imp.
(16.5 US) Gals = 62.5 lit.
Operator's manual
Check lighting system, indicator
lamps and instruments for proper
operation
Operator's manual
Check if speed control linkage moves
easily
Check engine idle speeds Section 20, group 40
Check injection timing Section 30, group 15 und 25
TESTING OPERATION
Check dual-stage clutch operation Approx. 1 in. (25 mm)
clutch pedal free travel
Section 50, group 5
Shift transmission through all speeds Operator's manual
Check differential lock operation Operator's manual
Check powershaft operation Operator's manual
Cheek 3-point hitch operation Operator's manual
Cheek hydraulic system operation Seetion 70, group 5
Cheek brake system Section 60, group 15
Check steering Section 60, group 10
Check seat adjustment Operator's manual
GENERAL
Tighten accessible nuts and attaching
screws
Seetion 10, group 20
Clean tractor and touch up paint

DELIVER Y INSPECTION
Model 820 Tractor
TO-4212 (Jan-70)
A thorough discussion of the operation and service
of the tractor at the time of its delivery helps to
assure complete customer satisfaction.
Proper delivery should be an important phase of
the dealer's program.
It is a well-known fact that many complaints have
arisen simply because the owner was not shown
how to operate and service his new tractor proper-
ly.
Enough time should be devoted, at the customer's
convenience, to introducing him to his new tractor
and explaining to him how to operate and service
it.
Using the tractor operator's manual as a guide, be
sure that the owner understands the following
points properly.
1. Adjusting the seat
2. Operation of control levers and instruments
3. Starting and shutting off the engine
4. The importance of the tractor break-in period
5. Use of counterweights and proper inflation
pressure as well as filling of tires with water and
magnesium chloride, if required.
6. Operating the complete hydraulic system
7. Operating the powershaft
8. The importance of the safety rules
9. The importance of lubrication and periodic
service
AFTER-SALES INSPECTION
In the interest of the purchaser and the dealer an
after-sales inspection should be carried out by the
dealer after the first 100 hours of using a new John
Deere tractor.
The purpose of this inspection is to make sure that
the customer is receiving satisfactory performance
Through this inspection a needless volume of ser-
vice work can be eliminated by preventing minor
difficulties from developing into serious problems
later on. It also will promote stronger dealer-
customer relations and give the customer an
opportunity to ask questions that may have arisen
during the first few days of use.
from his tractor. At the same time, the inspection
should reveal whether or not the tractor is being Thereby the dealer has the further opportunity of
operated, lubricated and serviced properly. promoting the possible sale of other new equip-
ment.
The following inspection program is recom-
mended:

Model 820 Tractor
TM-4212 (Jan-70)
Predelivery, Delivery and After-Sales Inspections 10-5
S e r v ic e S p e c iflc ct io n s R e f e re n c e
COOLING SYSTEM
Check coolant level
Clean exterior of radiator
Check hose connections
FUEL SYSTEM
Check sediment bowls and elements
of fuel filter as well as bowl of fuel
transfer pump for water or sediments
Check line connections
ELECTRICAL SYSTEM
Check gravity of battery electrolyte
Check electrolyte level of batteries
Check tension of fan belt
Start engine and check operation of
lights, indicator lamps and instruments
LUBRICATION
Check crankcase oil level
Check transmission oil level
Check oil level of steering
gear housing
Cheek oil level of belt pulley housing
Lubricate dual-stage clutch throw-out
Lubricate 3-point hitch
midway between radiator
filler neck
Gravity should be 1.260
at an electrolyte tem-
perature of 80OJ (27°C)
To bottom of filler neck
in eaeh cell
3/4 in. (19 mm) deflection
with a 20 lbs (9 kg) force
Top mark on dip stick
Add oil to filler hole
Add oil to filler hole
Operator's manual
. ........
Operator's manual
Operator's manual
Operator's manual and
section 20, group 35
Operator's manual
Operator's manual
Operator's manual
Operator's manual
Operator's manual
Operator's manual
Operaotr's manual

Model 820 Tractor
’I’M-4212 (Can-’70)
Service SpecticaMons R e f ez e xt c e
ENGINE
Fill with oil to level mark
Intake valve: 0.014 in
(o.3s mm)
Exhaust valve: 0.018 in.
(0.45 mm)
Approx. 1 in (25 mm)
free travel
Damaged paint, loose
connections, proper posi-
tioning of hoses and lines,
leaks, operation of all
mechanical parts
Check oil level in oil-bath air
cleaner
Operator's manual
Check dry-type air cleaner Operator's manual
Check valve clearance Section 20, group 10
Check engine speed under load as well
as fast and slow idle speed
Cheek engine performance Section 10, group 20
GENERAL
Check clutch pedal adjustment Section 50, group 5
Shift transmission through all speeds Operator's manual
Check operation of powershaft Operator's manual
Check differential lock Operator's manual
Ciieck operation of hydraulic system Section 70, group 5
Check steering system Section 60, group 10
Check brakes Section 60, group 15
Tighten accessible nuts and cap screws Section 10, group 20
Tighten accessible hydraulic lines
Visual inspection of tractor

Model 820 Tractor
TM•4212 (Jan-70)
Lubñcation and Adjustment 15-1
LUBRICATION AND ADJUSTMENT
For brands of oil and lubricants to be used as well as for lubricating and servicing the model g20
tractor, see operator's manual.

Model 820 Tractor
TM-4212 (Jan-70)
Engine and Tractor Tune-up 20-1
Group 20
ENGINE AND TRACTOR TUNE-UP
GENERAL INFORMATION
Before tuning up the engine, determine whether a doubt, the following preliminary tests will help to
tune-up will restore operating efficiency. If there is determine if the engine can be tuned up.
PRELIMINARY ENGINE TESTING
S e z v i c e S p e c iI ie a t i o n s R e I e r e n c e
Checking air intake system by
means of vacuum gauge
Check radiator for air bubbles
or oil film
Check compression pressure which
should be at least
(using special tool No. 19.58-90.578)
Measure engine horsepower at
powershaft
14 to 25 in. (355-635 mm)
water he-‹td; engine running
at fast idle speed
300 psi (21 kg/¢ 2)
Record measured perfor-
mance and compare with
performance measured after
carrying out “Engine
Tune-up”
“Fundamentals of Service,
Engine” manual under “Diag-
nosis and Testing”
Engine” manual under
“Diagnosis and Testing”
ENGINE TUNE-UP
AIR INTAKE SYSTEM
Dry-type air cleaner - clean filter
element and dust unloading valve
Oil-bath air cleaner - clean oil
cup and fill with fresh engine
oilto”Fufl“mazk
Check crankcase vent tube for
foreign particles (restriction)
Tighten cylinder head cap screws 110 ft.lbs (15 mkg)
Engine” manual.
“F undamentals of Service,
Engine” manual

lG General Information
20-2 Engine and Tractor Tune-up
Model 820 Tractor
TM-4212 (Jan-70)
ENGINE AND TRACTOR TUNE-UP-Continued
S er v ie e Specifications R e I eze n c e
Check and adjust valve clearance
BATTERIES
Thoroughly clean wires, connec-
tions and batteries
Tighten cable clamp screws
Liberally coat battery terminals
and cable connectors with
petroleum jelly
Check electrolyte level of battery
Check specific gravity of
electrolyte
GENERATOR
Check fan belt tension
FUEL SYSTEM
Check fuel tank and lines for leaks
or restriction
Remove bowl and strainer of fuel
transfer pump and clean
Check first stage filter element
and replace, if necessary
Check injection timing and adjust,
if necessary
Bleed fuel system
Check engine speeds and adjust
speed control linkage, if necessary
ENGINE LUBRICATION SYSTEM
Check engine oil pressure
Intake valve 0.014 in.
(0.35 mm)
Outlet valve 0.018 in.
(0.45 mm)
3/4 in. (19 mm) detection
with 20 lbs (9 kg) force
50 to 60 psi (3.5 to 4.2 kg/cm2)
at 2100 rpm
Operator's manual
Operator's manual
Section Z0, group 35
Section 30,group15,20 and25
Section 30, Group15,20 and 25
Section20, oup40

*,Index 8 20 Tractor
TM-4212 (Jan 7*!
ENGINE TUNE-UP - Continued
S e r v i c e S p e c i I i c a t i o n s Reference
COOLING 6“YSTEkJ
Ciean anci flush cooling system
Check radiator hoses for damage
and leaks
Clear radiator core of restrictions
Engine” manual
CHECKING ENGINE PER FORMANCE
After the engine has been tuned up as explained Compare measured performance in HP with output
above, determine powershaft horsepower by means measured before carrying out “Engine tune-up”.
of a dynamometer, see “Fundamentals of Service,
Engine” manual.
TRACTOR TUNE-UP
After carrying out engine tune-up, adjust tractor as follows:
S e rv i c e S p ecificatio ns R e I e r e n c e
ENGINE DUAL-STAGE CLUTCH
Adjust clutch pedal free travel Approx. 1 in. (25 mm) Section 50, group 5
FRONT WHEELS
Clean and lubricate front wheel Section 80, group 15
bearings
Adjust front wheel bearings Section 80, group 15
Check toe-in 1/8 to 3/8 in. (3 to 9.5 mm) Section 60, group 5
Check torque of front wheel 85 ft.lbs (12 mkg)
bolts
HYDRAULIC BRAKES
Bleed brake system Section 60, group 15

20-4 Engine and Tractor Tune-up
Model 820 Tractor
TM-4212 (Jan-70)
TRACTOR TUNE-UP - Continued
S e r v i c e S p e c i f ic a t i o n s R e f er e n e e
HYDRAULIC SYSTEM
Cheek operating pressure 2000 psi (140 kg/pjjj2) Section 70, group 5
Check rockshaft lift cycle time 2.5 sec. Section 70, group 5
at 2100 rpm engine speed
TIRES
Check tire inflation pressure Operator's manual
TORQUES
Check all accessible cap screws
and nuts of tractor for proper
Torque chart
torque

Mendel 820 ’Frac ior General Information 10
STANDARD TORaUES
Recommended torques in ft. lbs. and mkg for UNC and UNF
cap screws
Head marking
(identifying
strength)
6.8
or
(6. S)*
or
10.9 (10 K)**
or
12.9 (12 K)***
Thread-O.D. (in.) ft Jbs. t mkg ftdbs. mkg ftJbs. mkp
1/4 7 1 10 1,5 14 2
5 ’16 14 2 20 3 30 4
3/8 21 3 35 5 50 7
7/16 35 ? 55 8 80 11
1/2 55 8 85 12 130 18
9/16 75 10 130 18 185 26
5/8 105 15 170 23,5 250 34,5
3/4
7/8
185 25,5
160*”** 22“"””
300
445
41,5
61,5
420
670
58
92,5
1 250 34,? 670 92,5 1000 138.5
NOTE: A variatton o f + 10% is permissible for all torques ind icat ed in
tiiis ciiart.
Torque figures indicated above and in the repair data sections of this manual
are valid for non-greased or non-oiled threads and heads unless otherwise
specified.
Regular bolts and cap screws
Tempered steel high strength bolts and cap screws
*** Tempered steel extra high strength bolts and cap screws
Bolts and screws 7/8 in. and larger are often formed hot rather than
cold, which accounts for the lower torque.
Part N o. if ordered through
JD Parts Depot ManuIact urer
19.58-90-578
19.58-90-260* . .
Details see section 70, group 5
SPECIAL TOOLS
Descrip tion
Special adapter
Special tool
Use
Checking compression pressure
Checking oi1 pressure

Model 820 Tractor
TM-4212 (Jan-70)
Separation 25-1
Group 25
SEPARATION
SEPARATlN€ BETWEEN ENGINEANDTRACTOR FRONT END
REMOVAL
For safety disconnect battery cable.
Remove front end weights (if equipped).
Remove radiator and fuel tank caps. Remove
radiator side grilles and hood. Install radiator and
fuel tank caps. Remove side frames.
Gose fuel shut-off valve at bottom of fuel tank.
Disconnect fuel inlet line at fuel tank and transfer
pump. Remove transfer pump and fuel inlet line.
Fig. 2 — Disconnecting Hydraulic Lines on Tractors
with Collar-shift Transmission
1 Suction line
of bydxau1ilc puaip
2 Retainer
3 Rpe csoaps
4 Pressure line of
hvdraulic pump
5 Cap screw
Fig. 1 — Separating between Tractor Front End and
Engine
Remove pipe clamps 3 (fig. 2). Remove cap screw
5 and retainer 2 for attaching suction line l to
1 Cap screws
2 Distributor
3 Cable of fuel
gauge sending unit
d Fuet return line
6 Upper water hose
6 Air intake pipe
front of clutch housing. Disconnect pressure line 4
at connector.
Disconnect air intake pipe 6 at intake manifold of
engine.
Drain coolant and disconnect upper and lower
water hose at radiator.
5 2

25-2 Separation
NOTE: Plug lines and openings immediatel y with
plugs or caps.
Disconnect drag link at bell crank. Securely
support rear of tractor under clutch housing.
Insert wood blocks between front axle and front
support to prevent the latter from tipping
sideways.
Attach front of tractor to a suitable hoist.
Remove cap screws 1 (fig. 1) of front support and
separate front end from engine. Take measures to
prevent front of tractor from tipping to the front.
If tank contains too much fuel, drain it or safely
support front of tractor.
CAUTION: Move front end forward out of tractor
until pump drive shaft comes loose of front or rear
coupling of pump drive.
INSTALLATION
Install hydraulic pump drive shaft into front
coupling. Make sure both dowels are in place on
front support.
Move front of tractor toward engine. Be sure to
install hydraulic pump drive shaft in rear coupling,
and to install suction line 1 (fig. 2) in clutch housing.
Attach front end of tractor to engine, using cap
screws 1 (fig. 1). Tighten screws to the specified
torque.
Model 820 Tractor
TM-4212 (Jan-70)
Install retainer 2 (fig. 2) of suction line 1 and
tighten cap screw 5 of retainer to the specified
torque. Connect pressure line 4.
NOTE: yor proper sealing o[ suction line, place a
new O-ring in clutch housing bore.
Install fuel transfer pump and connect fuel lines.
Make sure transfer pump inlet line is below and
behind fuel pressure line.
Open fuel shut-off valve.
Connect wire to fuel gauge sending unit.
Connect headlight wires to junctions.
Attach water hoses to radiator.
Attach air intake pipe to intake manifold.
Install clamps of hydraulic lines
Attach drag link to bell crank and tighten slotted
nut to the specified torque.
Install hood and radiator side grilles.
Fill radiator with clear, soft water, adding an
antifreeze-rust inhibitor mixture (see Operator's
Manual).
Connect ground cable to batteries.
CAUTION: Always connect ground cable to
negative (-) poles of batteries.
Start engine and check fuel lines, hydraulic lines
and water hoses for possible leaks.

4Iodel 820 Tractor
TH-4212 (Jan-70)
Separation 25-3
REMOVING AND INSTALLING ENGINE
NOTE: for most engine service operations the
engine need not be removed. Hou›ever, i[ the
crankshaft has to be removed or in case o/ mojor
overhaul, re move engine.
REMO¥’AL
Por safety disconnect ground cable at batteries.
Separate front of tractor ftom engine, as explained
above.
Disconnect all cables to dashboard at regulator
and all cables 4 (fig. 3) at starter.
Disconnect cable at oil pressure switch 3.
Fig. 4 — Separating between Engine and Clutch
Housing, L.H. side
1 Engine attaching screws
Pig. 3 — Separating between Engine and Clutch
Housing, R.H. Side
1 En@ne atacRag 9ozews 3 Ofi preswze swdeb
2 £Jexi4e sbaf¢ of txcbomeer 4 Surfer cable
Remove flexible shaft 2 (fig. 3) of tachometer
from clutch housing and cam shaft. Replace rubber
seal of flexible shaft, if required (seal will possibly
remain in housing bore).
Remove cap screws S attaching dash to flywheel
housing.
Disconnect wire at signal horn.
On tractors wit A starting ftuid adapter: Disconnect
starting fluid line at intake manifold.
in tractors uiith Thermostart aid: Disconnect
cable at heater of intake manifold.
Disconneci speed control rod 2 (Fig. 41 at injection
pump
On trocfors with BOiSCH or ROTO DUBEI
injection putrip: Disconnect shut-off cable at the
pump.
On tmetors with ROOiSA MAS!TER model CB
i•ieetiOn R* p1 Disconnect shut-off cable at the
pump.
Screw retaining screw of flexible tube of coolant
temperature gauge out of cylinder head and
withdraw flexible tube from cylinder head.
Remove left dash panel as well as both batteries.
Remove cap screws attaching dashboard to
flywheel housing.
Attach JD 244-1 and 244-2 engine lifting eyes to
cylinder head and attach engine to a suitable hoist.
Remove cap screws 1 (tigs. 3 and 4) attaching
flywheel housing to clutch housing.
Lift engine out front by means of the hoist.

25-4 Separation
CAUTION: Move engine properly in line with drive
shaft and hollow drive shaft until these shafts come
loose of the driven disks of the engine dual-stage
clutch.
INSTALLATION
Align engine properly with drive shaft and hollow
drive shaft and move toward rear Of tractor. Align
splines of both shafts with internal threads of
driven disks. Also align screw holes of flywheel
housing with screw holes of clutch housing. Slide
engine evenly toward clutch housing, inserting two
dowels of flywheel housing in bores of clutch hou-
sing until engine fully contacts clutch housing.
CAUTION: Make sure flywheel housing is flush
against clutch housing before tightening screws.
Then tighten attaching screws to the specified
torque.
Secure dash to flywheel housing.
Connect speed control rod to injection pump.
On tractors with BOSCH or ROTO DIESEL
in/ection pump: Attach shut-off cable to pump.
On tractors with ROOSA MASTER model CB
iriJectioti pump: Connect shut-off cable to pump.
Model 820 Tractor
TM-4212 (Jan-70)
lnsert flexible tube of coolant temperature gauge
in cylinder head and tighten retaining screw.
Connect cables to regulator and starting motor and
connect cable to oil pressure switch.
Connect cable to signal horn.
Install both batteries.
CAUTION: Connect battery cable to positive poles
of batteries.
Lubricate rubber seal of tachometer flexible shaft
and attach shaft to clutch housing (see 2, fig. 3).
Make sure driving tab of flexible shaft engages in
slot of camshaft. Do not tighten excessively to
avoid damage to the seal resulting in leakage.
On tractors north starting fluid adapter: Connect
starting fluid line to intake manifold.
On tractors with Thermostart aid: Connect
Thermostart aid wire to heater in intake manifold.
Attach front of tractor to engine.
CAUTION: Connect ground cables of batteries to
negative (-) poles.
NOTE: I f engine has been overhauled, tune up
engine as explained in group 20.
REMOVALAND lNSTALLATlON OFCLUTCH HOUSING
NOTE: !Separating and attaching o/ engine and Separate engine from clutch housing as explained
clutch housing as uiell as of clx tcJt housing and under ”REMOVING ENGINE”; the tractor front
transmission case is explained below. JPhere the end may remain attached to the engine.
tractor is to be separated depends on the individual
repair operation. I{, e.g., repair worn has to be
carried out on the transmission, separation Remove clamps 3 (fig. 2), cap screw 5 and retainer
between the clutch housing and the transmission 2 for fastening suction line 1 to front clutch
case will be sufficient. housing. Disconnect pressure line 4 (fig. 2) at
connector.
REMOVAL
Disconnect battery ground cables.
Drain transmission oil.

Model 820 Tractor
TM-4212 (Jan-70)
Disconnect drag link at bell crank.
Insert wood blocks between front axle and front
support to prevent front support from tipping
sideways.
Safely support rear end of tractor.
Attach tractor front end and engine to a suitable
hoist and remove attaching screws 1 between
engine and clutch housing (see figs. 3 and 4).
Roll engine and tractor front end away from clutch
housing.
Remove oil line of front quick coupler (if
provided). Remove right footrest.
Disconnect brake lines at brake valve and cylinder.
Remove transmission shield.
Remove clamp of pump pressure line at clutch
housing.
Fig. 5 — Separating between Glutch Housing and
Transmission Case, L.H. Side
Separation 25-5
Remove transmission shift cover 3 (fig. 5).
Remove transmission oil filter.
Remove cap screws 1 (fig. 5) on both sides and both
inner cap screws. Separate clutch housing from
transmission case.
Discard seal rings provided between the two
housings.
NOTE: Be sure ball and spring provided on some
po wersho/f t y pes do not get lost (see section 50,
group 25).
INSTALLATION
Install new seal rings in clutch housing front facing
transmission case.
Slide clutch housing against transmission case.
Slide PTO drive shaft into bore of front PTO shaft
or (if front PTO is not provided) into bore of quill.
Make sure spring and ball provided on some
powershaft types are installed in PTO drive shaft or
quill or front powershaft. Align clutch housing
with centerline of PTO drive shaft and slide against
transmission case. Mesh powershaft gears with
splines of hollow PTO drive shaft.
Make sure clutch housing is flush against transmis-
sion case before tightening cap screws to the
specified torque.
NOTE: If clutch housing has also been separated
from engine, assemble a8 explained under
”Installation of Engine.”
Install suction line 1 (fig. 2) in bore of clutch
housing and secure by means of screw and retainer.
Tighten cap screw to the specified torque. Connect
front section of pressure line 4 (fig. 2) to rear
section. Then install both pipe clamps 3.
NOT£: For proper sealing of suction line, insert
new O-ring in bore o[ clutch housing.
As regards further installation operations reverse
removal procedure.
1 Attaching screa's
2 Wiring barness
3 Trazzszoisston sbitt cover
4 Cable of starter satetx
switcb CAUTION : Connect ground cable of batteries to
negative (-) poles.
Remove both harnesses to rear fenders at con-
nectors. Disconnect cable at starter safety switch
and cables at brake light switch.

L+8397
25-6 Separation
Model 820 Tractor
TM-4ZI2 (Jan-70)
REMOVAL
REMOVAL AND INSTALLATION OF FINAL DRIVES
Disconnect pilot line 5 (fig. 6) at dump valve and
rockshaft and remove. Remove clamp 7.
NOTE. The removal o[ both final driues is
explained below. I f onI y one final drive is to be
removed, remove only one wheel, wiring harness
etc.
For safety disconnect ground cable at batteries.
Lift up rear of tractor by means of a car jack or
hoist and remove rear wheels.
CAUTION: Support transmission safely to prevent
tipping of tractor.
Disconnect both rear wiring harnesses at
connectors.
Remove rear fender.
Disconnect cables at brake warning switch located
in left-hand rear axle housing.
Disconnect brake lines on both rear axle housings.
Fig. 6 — Oil Manifold and Pressure Control Valve
Installed
Disconnect both pressure lines 3 and 4 at elbows
and return line 8 oil manifold 1. On tractors with
selective control valve disconnect line to quick
coupler at control valve. Remove two cap screws 6
attaching oil manifold 1 to right final drive
housing. Lift off oil manifold with pressure control
valve and selective control valve (if equipped),
Cover connections and exposed openings with
plastic plugs or caps to keep out foreign particles.
Fig. 7 — Removing Final Drive
1 Final drive bousing
3 Pr ersure ztng 4 Final ‹lrive shaft
Attach tinal drive to hoist. Remove finn dnve
attaching screws and pull final drive housing from
transmission case. Withdraw housing evenly until
final drive shaft gear is no longer in mesh with
planetary gears of final drive.
INSTALLATION
NOTE: I f the bra he dish and the ”Roofing” facing
mere removed, install bonded two-layer {acing so
that the brass- interwoven upper layer faces the
brake curface of the transmission case.
Position new gasket between final drive housing
and transmission case.
Attach final drives to transmission case by means
of a suitable hoist. Make sure final drive shaft gear
2 Pcessuze cozttzol
valve
3 Pzessuxe Me
5 ÜOtl ZQ
atte.ckîng sczews
8 Return Ïîne
indexes with planetary gears and that the dowels
are properly aligned.
Tighten final drive attaching screws to the
specified torque.

Model 820 Tracior
TM-4212 (Jan-70)
Separation 25-7
Attach oil manifold with pressure control valve and Install rear fenders. Connect lines of wiring
selective control valve (if equipped) to final drive harnesses to connectors.
housing.
Connect all oil lines and install pipe clamp.
Connect brake lines and bleed brakes, as explained
in section 60, group 15.
Connect cable to brake warning switch,
Install rear wheels and tighten to the specified
torque.
CAUTION: Tighten ground cable to negative (-)
poles of batteries.
REMOVAL AND INSTALLATION OF ROCKSHAFT
REMOVAL
IMPORTANT: Work on the hydraulic system
requires extreme care and cleanliness. Minute dirt
or foreign particles, scratches, nicks or burrs may
put the hydraulic system out of function. Before
removing the rockshaft, check hydraulic system for
leaks.
For safery, disconnect ground cable from batteries.
Remove transmission shield. Disconnect line l (fig.
8) of starter safety switch.
Remove operator's seat. Disconnect both lift links
at lift arms.
Fig. 8 — Rockshaft, Installed
1 I zte oF Starter 2 Pitot line
3 Oil zeturn line
Loosen clamp of oil return hose S (fig, 8) facing
rockshaft and move aside.
Disconnect lines of rear quick couplers (if
equipped) at selective control valves.
Disconnect pilot line 2 (big. 8) at elbow on
rockshaft.
Free both rear wiring harnesses.
Move selector lever in position ”L” so that the
control linkage roller slides along the cam of the
control arm when removing the rockshaft.
Attach engine lifting eye No. JD 244-2 to top of
rockshaft housing.
Remove rockshaft attaching screws (see arrows in
fig. 8). Lift rockshaft assemblé off transmission
case by means of a hoist. Withdraw oil return line 3
from rockshaft adapter.
Take care not to damage two rear harnesses.
NOTE: A[ter removing rochsha[t, couer
transmission case to prevent (oreign particles /rotn
[alling into the transmission.
INSTALLATION
Use a new gasket between transmission case and
rockshaft. Make sure dowels in transmission case
and seal ring of oü înlet passage are installed.
Move selector lever in position ”L” so that the
control linkage with roller can be slided over the
cam.
Lift rockshaft on transmission case, using a suitable
hoist.

25-8 Separation
Model 820 Tractor
TM-4212 (Jan-70)
Connect oil return line 3 an4 Pilot line 2 to Install transmission shield on transmission ease.
rockshaft.
For adjustment of rockshaft see section 70, group
Tighten roekshaft attaehing serews to the specified 20
torque.
GAUTlON: Connect ground cable of batteries to
Connect cable of starter safety switch. negative poles.
Connect both rear wiring harnesses to rockshaft.
TOHOUES FOR HAHOWAH E
Front support to engine, cap serews .....................................................170 ft.lbs.
Drag link to bell crank or steering arm,
23,5 mkg
slotted nut*
Gutch housing to engine, cap serews
Clutch housing to transmission case, cap serews
Retainer of suction line
. 55 ft.lbs.
. 170 ft.lbs.
. 85 ft.lbs.
7,7 inkg
23,5 mkg
11.7 mkg
to clutch housing ....................................................................................32 ft.lbs.
Final drives to transmission case, cap screws...........................................8f5
t.lbs.
Rockshaft housing to transmission ease, cap screws ...............................85 ft.lbs.
Rear wheels to rear axle, wheel bolts .......................................................85 ft.lbs.
4,5 mkg
11.7 mltg
11,7 mkg
11.7 mkg
* NOTE: IQ cotter pin connor
and secure u›ith cotter pin.
Part No. when ordening from
ID Parts Depot Manufacturer
be inserted mhen figùteiiirig to the speeified torque, turn nut to nent slot
SPECIAL TOOLS
Description Use
L 48524 ....... ID 244-1** .......... >iftiIlg12ye, Straight...........................Removing and instal-
ling assemblies
L 48525 ........ ID 244-2** .......... Lifting eye, bent............................... Ditto
** OWATONNA TOOL COMPANY, OWATONNA/MINNESOTA 55060, USA

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John Deere 820 Tractor Service Technical Manual.pdf