John Deere Tractors 5415, 5415N; 5415H, 5615, 5615HC; 5715, 5715HC Diagnostic and Repair Service Manual - TM6019

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Price: US$ 55.00

John Deere Tractors 5415, 5415N; 5415H, 5615, 5615HC; 5715, 5715HC Diagnostic and Repair Service Manual - TM6019

tm6019 - 5415, 5415 Narrow, 5415 Orchard, 5615, 5715 and 5715HC Tractors Technical Manual.pdf

Complete All Inclusive Technical Manual with electrical wiring diagrams for 5415, 5415N, 5415H, 5615, 5615HC, 5715, 5715HC, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere Tractors 5415, 5415N, 5415H, 5615, 5615HC, 5715, 5715HC workshop technical service manual 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.
* 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.

MAIN SECTIONS
 Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features and Accessories
   Engine Repair
      Engine
      Cooling System
   Fuel and Air Repair
      Fuel System
      Fuel System - 5415 Narrow
      Air Intake System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing
      Clutch Assembly
      LUK Clutch Assembly
      CollarShift/SyncShuttle™ Transmission
      Rear PTO Drive Shaft
      Differential
      Final Drives
      5715HC Final Drives
      Mechanical Front Wheel Drive
      Creeper Assembly
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter 5415 (......-001492) 5615 (......-001694) and 5715 (......-002112)
      Hydraulic Pump and Filter 5415 (001493-......) 5615 (001695-......) and 5715 (002113-......)
      Hydraulic Oil Cooler
      Rockshaft
      Rockshaft 5415 Narrow
      Dual Selective Control Valve
      Single Selective Control Valve
      Selective Control Valve (SCV) 5415 Narrow
      Hydraulic Power Beyond
      Hydraulic Power Beyond 5415 Narrow
   Miscellaneous Repair
      Front Axle-2WD
      Wheels
      3-Point Hitch
      3-Point Hitch 5415 Narrow
      Final Drive Axle Spacers
   Operator Station Repair
      Seat and Support
      Control Console and Panel
      Fenders 5415 Narrow
      ROLL-GARD®
      ROLL-GARD 5415 NarrowROLL-GARD is a trademark of Deere & Company.
      Rear Bar 5415 Narrow
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Fuel/Air Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Electrical System Operation, Test & Adjust
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
      Wiring Schematics
   Power Train Operation, Tests and Adjustments
      Component Location-Collar Shift/SyncShuttle™ Transmission
      Theory of Operation-Collar Shift/SyncShuttle™ Transmission
      Diagnosis, Tests and Adjustments-CS/SS Transmission
   Steering and Brake Operation, Test & Adjust
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests-Without SCV
      Hydraulic Tests-With SCV
      Hydraulic Tests-All
      Adjustments
      Hydraulic Schematics
   Dealer Fabricated Tools

Total Pages: 1,454 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

tm6019 - 5415, 5415 Narrow, 5415 Orchard, 5615, 5715 and 5715HC Tractors - Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service Cooling System Safely

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

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 10: General Specifications

Machine Specifications 5415, 5415 Narrow, 5415 Orchard, 5615, 5615HC, 5715 and 5715HC

Machine Specifications 5415, 5415 Narrow, 5415 Orchard, 5615, 5615HC, 5715 and 5715HC - Continued

Machine Specifications 5415, 5415 Narrow, 5415 Orchard, 5615, 5715 and 5715HC

Ground Speed Estimates

Ground Speed Estimates (Narrow)

Repair Specifications

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Repair Specifications - Continued

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values—Grade 7

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Abbreviations

Group 20: Fuel and Lubricants

Diesel Fuel Specifications

Lubricity of Diesel Fuel

Diesel Fuel Storage

Do Not Use Galvanized Containers

Fill Fuel Tank

Diesel Engine Oil

Engine Break - In Oil

Engine Cooling System

Liquid Coolant Conditioner

Transmission and Hydraulic Oil

MFWD Gear Oil

Grease (Specific Application)

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Group 25: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Fuel Injection Pump Serial Number Location

Alternator Serial Number Location

Power Steering Valve Serial Number Location

Starter Serial Number Location

Transmission Serial Number Location

Front Axle Serial Number Location

Mechanical Front Wheel Drive (MFWD) Serial Number Location

Group 30: Features and Accessories

Features and Accessories

Standard Features

Standard Features

Standard Features

Operating Foldable Rops

Fixed Rops Crossbar

Factory Installed Optional Equipment

Field Installed Optional Kits and Accessories

Section 20: Engine Repair

Group 05: Engine

John Deere Engine Repair-Use CTM104

Remove Engine

Install Engine

Group 10: Cooling System

Engine Water Pump Repair—Use CTM104

Remove and Inspect Radiator

Install Radiator

Replace Thermostat

Inspect and Replace Belt Tensioner

Section 30: Fuel and Air Repair

Group 05: Fuel System

Injection Pump, Nozzle and Governor Repair—Use CTM104

Remove, Inspect and Install Fuel Tank

Replace Fuel Filter

Remove and Install Fuel Filter/Primer Pump Assembly

Remove and Install The Water Separator Assembly

Group 06: Fuel System - 5415 Narrow

Injection Pump, Nozzle and Governor Repair—Use CTM104

Remove, Inspect, and Install Fuel Tank

Replace Fuel Filter

Remove and Install Fuel Filter/Primer Pump Assembly

Remove and Install The Water Separator Assembly

Group 10: Air Intake System

Turbocharger Repair—Use CTM104

Remove, Inspect, and Install Air Cleaner Elements

Air Pre-Cleaner

Remove Turbocharger 5715 - 5715HC

Install Turbocharger 5715 - 5715HC

Turbocharger Break-In

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Starter Repair—Use CTM77

Remove and Install Battery

Remove and Install Starter

Replace Alternator/Regulator - 40 AMP

Group 10: Electrical System Components

Other Material

Replace Air Filter Restriction Switch

Replace Coolant Temperature Sender

Replace Engine Speed Sensor

Replace Engine Oil Pressure Switch

Replace Manifold Heater

Replace Manifold Heater Relay

Replace Key Switch

Replace Tractor Light Switch

Replace Turn Signal Controller

Replace Instrument Panel

Replace Rear PTO Switch

Replace Neutral Start Switch

Replace Fuel Level Sender

Replace Park Brake Switch - 5415 NARROW

Group 15: Wiring Harness

Special or Essential Tools

Tools

Service Parts Kits

Replace Connector Body—Blade Terminals

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace Front Wiring Harness

Replace Rear Wiring Harness

Section 50: Power Train Repair

Group 05: Clutch Housing

Other Material

Service Parts Kits

Separate Engine from Clutch Housing

Install Engine to Clutch Housing

Replace Clutch Housing Seal

Inspect and Repair Clutch Pedal and Linkage

Group 10: Clutch Assembly

Special or Essential Tools

Tools

PTO Clutch Finger Height Gauge

Traction Clutch Finger Height Gauge

Traction Clutch Finger Height Adjustment Tool

Other Material

Service Parts Kits

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

Traction Clutch Finger Adjustment

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Group 11: LUK Clutch Assembly

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

Traction Clutch Finger Adjustment

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Group 15: CollarShift/SyncShuttle™ Transmission

Other Material

Separate Clutch Housing From Transmission

Install Clutch Housing to Transmission

Inspect and Repair Gear Shift Lever5415, 5615 y 5715 ( -003591) Series5415 (004531- ) Series

Inspect and Repair Range Shift Lever5415, 5615 y 5715 ( -003591) Series5415 (004531- ) Series

Inspect and Repair Gear and Range Shift Levers5415 (003592-004530) Series5615 y 5715 (003592- ) Series

Remove Transmission

Remove, Inspect and Repair Gear Shift Lever 5415 Narrow

Remove, Inspect and Repair Range Shift Lever 5415 Narrow

Remove Transmission 5415 Narrow

Disassemble and Inspect Transmission5415, 5615 y 5715 ( -003591) Series 5415 (004531- ) Series

Assemble Transmission5415, 5615 y 5715 ( -003591) Series 5415 (004531- ) Series

Install Transmission 5415, 5615 y 5715 ( -003591) Series 5415 (004531- ) Series

Disassemble and Inspect Transmission Serie 5415 (003592-004530)Series 5615 y 5715 (003592- )

Assemble Transmission Serie 5415 (003592-004530)Series 5615 y 5715 (003592- )

Install Transmission Serie 5415 (003592-004530)Series 5615 y 5715 (003592- )

Disassemble, Inspect and Assemble Gear Shift Shaft Assemblies

Disassemble, Inspect, and Assemble Transmission Top Shaft—CollarShift Transmission

Disassemble, Inspect, and Assemble Transmission Top Shaft—SyncShuttle™ Transmission

Disassemble, Inspect, and Assemble Range Reduction Shaft

Disassemble, Inspect and Assemble Driven Shaft

Remove, Inspect, and Install MFWD and Range Gears

Remove, Inspect, and Install Reverse Idler Shaft

Inspect and Repair Park Brake Lever 5415 Narrow

Remove, Inspect, and Repair Park Brake 5415 Narrow

Group 20: Rear PTO Drive Shaft

Other Material

Inspect and Repair Rear PTO Lever and Linkage

Remove and Install Standard Rear PTO Drive Shaft Assembly

Disassemble, Inspect and Assemble Standard Rear PTO Drive Shaft Assembly

Inspect and Repair PTO Lever and Linkage 5415 Narrow

Group 25: Differential

Special or Essential Tools

Tools

Other Material

Service Parts Kits

Remove and Install Differential Assembly

Disassemble, Inspect, and Assemble Differential Assembly

Remove and Inspect Differential Drive Shaft

Install Differential Drive Shaft

Remove, Inspect, and Install Differential Lock Assembly

Differential Cone Point Adjustment

Differential Backlash Adjustment

Group 30: Final Drives

Service Equipment and Tools

Other Material

Remove and Install Final Drive Assembly

Remove and Inspect Planetary Drive Assembly

Install Planetary Drive Assembly

Remove, Inspect, and Install Axle Shaft Assembly

Group 31: 5715HC Final Drives

Service Equipment and Tools

Other Material

Remove Final Drive Assembly

Final Drive Assembly

Group 35: Mechanical Front Wheel Drive

Special or Essential Tools

Tools

Other Material

Inspect and Repair MFWD Lever and Linkage

Inspect and Repair MFWD Lever and Linkage–5415 Narrow

Remove and Install MFWD Drop Gearbox

Disassemble and Inspect MFWD Drop Gearbox

MFWD Drop Gearbox Cross Section

Assemble MFWD Drop Gearbox

Remove, Inspect and Install MFWD Drive Shaft

Remove, Inspect, and Install MFWD Drive Shaft - 5415 Narrow

Remove and Install MFWD Axle Housing Assembly

Remove and Install MFWD Axle Housing Assembly - 5415N

Remove and Install MFWD Axle Pivot Pin and Pivot Bushings - 5415N

Remove, Inspect and Install MFWD Axle Supports–Later Version

Remove, Inspect and Install MFWD Axle Supports–Early Version

Disassemble and Inspect MFWD Outer Drive–Later Version

Disassemble and Inspect MFWD Outer Drive–Early Version

Disassemble and Inspect MFWD Outer Drive - 5415N

Assemble MFWD Outer Drive–Later Version

Assemble MFWD Outer Drive–Early Version

Assemble MFWD Outer Drive–5415N

Remove, Inspect and Install MFWD Knuckle Housing

Repair the Knuckle Housing and the King Pin–Early Version

Repair the Knuckle Housing and the King Pin - 5415N

Remove, Inspect, and Install MFWD Axle Shaft–Later Version

Remove, Inspect, and Install MFWD Axle Shaft–Early Version

Remove, Inspect, and Install MFWD Axle Shaft - 5415N

Remove and Install MFWD Differential Carrier Assembly

Disassemble and Inspect MFWD Differential Carrier Assembly–Later Version

Disassemble and Inspect MFWD Differential Carrier Assembly–Early Version

Assemble MFWD Differential Carrier Assembly–Later Version

Assemble MFWD Differential Carrier Assembly–Early Version

Filling/Draining Planetary Drive

Filling/Draining MFWD Axle Housing

Group 40: Creeper Assembly

Other Material

Remove and Install Creeper Assembly

Disassemble, Inspect, and Assemble Creeper Assembly

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Other Material

Service Parts Kits

Remove and Install Steering Column and Valve

Disassemble and Inspect Steering Valve

Assemble Steering Valve

Remove and Install Steering Cylinder—2WD Axle

Remove and Install Steering Cylinder—2WD Axle (5415N)

Remove and Install Steering Cylinder—2WD Axle (High Clearance Tractors)

Disassemble, Inspect, and Assemble Steering Cylinder—2WD Axle

Disassemble, Inspect, and Assemble Steering Cylinder—2WD Axle (5415N)

Disassemble, Inspect, and Assemble Steering Cylinder—2WD Axle (High Clearance Tractors)

Remove and Install Steering Cylinder— Later MFWD Axle

Remove and Install Steering Cylinder—Early MFWD Axle

Remove and Install Steering Cylinder—MFWD Axle (5415N)

Disassemble, Inspect, and Assemble Steering Cylinder— Later MFWD Axle

Disassemble, Inspect, and Assemble Steering Cylinder— Early MFWD Axle

Disassemble, Inspect, and Assemble Steering Cylinder— MFWD Axle (5415N)

Remove, Inspect and Install Tie Rod Assembly—2WD Axle

Remove, Inspect and Install Tie Rod Assembly—2WD Axle (High Clearance Tractors)

Remove, Inspect and Install Tie Rod Assembly—2WD Axle (5415N)

Remove, Inspect and Install Tie Rod Assembly—Later MFWD Axle

Remove, Inspect and Install Tie Rod Assembly—Early MFWD Axle

Remove, Inspect and Install Tie Rod Assembly—MFWD Axle (5415N)

Inspect and Replace Steering Hydraulic Lines (Without Oil Cooler) 5415

Inspect and Replace Steering Hydraulic Lines (With Oil Cooler) 5615-5715

Group 10: Brake Repair

Other Material

Remove and Install Brake Valve and Pedals

Disassemble and Inspect Brake Valve

Brake Valve Cross Section

Assemble Brake Valve

Remove and Inspect Brakes

Install Brakes

Inspect and Replace Brake Hydraulic Lines

Section 70: Hydraulic Repair

Group 05: Hydraulic Pump and Filter 5415 (......-001492) 5615 (......-001694) and 5715 (......-002112)

Service Parts Kits

Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen

Remove and Install Hydraulic Pump

Remove Hydraulic Pump External Components

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Install Hydraulic Pump External Components

Remove and Install Hydraulic Oil Filter/Manifold

Inspect and Replace Hydraulic Supply/Return Lines

Inspect and Replace Hydraulic Supply/Return Lines (5415 NARROW)

Group 06: Hydraulic Pump and Filter 5415 (001493-......) 5615 (001695-......) and 5715 (002113-......)

Service Parts Kits

Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen

Remove and Install Hydraulic Pump

Remove Hydraulic Pump External Components

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Install Hydraulic Pump External Components

Group 07: Hydraulic Oil Cooler

Remove, Inspect, and Install Hydraulic Oil Cooler

Group 10: Rockshaft

Other Material

Service Parts Kits

Inspect and Repair Rockshaft Control Lever Assembly

Inspect and Repair Rockshaft Control Linkage

Inspect and Repair Draft Sensing Support Assembly

Replace Main Relief Valve

Replace Rockshaft Surge Relief Valve

Remove, Inspect, and Install Rate-of-Drop Valve

Replace Rockshaft Control Valve

Remove and Install Rockshaft Case

Remove, Inspect, and Install Rockshaft Lift Arms

Remove, Inspect, and Install Rockshaft Piston and Cylinder

Group 11: Rockshaft 5415 Narrow

Other Material

Service Parts Kits

Inspect and Repair Rockshaft Control Lever Assembly

Group 15: Dual Selective Control Valve

Other Material

Service Parts Kits

Remove and Install Dual Selective Control Valve (SCV)

Disassemble, Inspect, and Assemble Dual Selective Control Valve (SCV)

Inspect and Replace Hydraulic Hoses—Dual Selective Control Valve (SCV)

Group 16: Single Selective Control Valve

Other Material

Service Parts Kits

Inspect and Repair SCV Levers and Linkage

Remove and Install Single Selective Control Valve (SCV)

Disassemble, Inspect, and Assemble Single (Third) Selective Control Valve (SCV)

Inspect and Replace Hydraulic Hoses—Single (Third) Selective Control Valve (SCV)

Group 17: Selective Control Valve (SCV) 5415 Narrow

Other Material

Service Parts Kits

Remove and Install Selective Control Valve (SCV)

Disassemble, Inspect, and Assemble Selective Control Valve (SCV)

Group 20: Hydraulic Power Beyond

Remove and Install Hydraulic Lines and Fittings—Power Beyond Hook-Up

Remove and Install Hydraulic Lines and Fittings—Power Beyond Hook-Up - Continued

Group 25: Hydraulic Power Beyond 5415 Narrow

Install and Remove Hydraulic Lines and Fittings—Power Beyond Hook-Up

Section 80: Miscellaneous Repair

Group 05: Front Axle—2WD

Remove and Install Front Axle—2WD

Remove and Install Front Axle—2WD (5415N)

Remove and Install Front Axle—2WD (High Clearance Tractors)

Inspect and Replace Pivot Pin and Bushings—2WD Axle

Remove and Install Spindle Assembly—2WD Axle

Remove and Install Spindle Assembly—2WD Axle (5415N)

Remove and Install Spindle Assembly—2WD Axle (High Clearance Tractors)

Inspect and Replace Spindle Shaft Bushings—2WD Axle

Group 10: Wheels

Inspect and Replace Front Wheel Bearings - 2WD

Inspect and Replace Front Wheel Bearings - 2WD (5415N)

Inspect and Replace Front Wheel Bearings - 2WD (High Clearance Tractors)

Group 15: 3-Point Hitch

Inspect and Repair Fixed Draft Links

Inspect and Repair Telescoping Draft Links

Inspect and Repair Standard Lift Link

Inspect and Repair Adjustable Lift Link

Inspect and Repair Center Link

Remove and Install Drawbar and Support

Drawbar and Support (Continued)

Group 20: 3-Point Hitch 5415 Narrow

Inspect and Repair Draft Links

Inspect and Repair Adjustable Lift Links

Inspect and Repair Center Link

Remove and Install Drawbar and Support

Group 25: Final Drive Axle Spacers

Prepare Tractor

Install Axle Spacers

Section 90: Operator Station Repair

Group 05: Seat and Support

Remove and Install Seat and Support

Group 06: Control Console and Panel

Remove and Install Right-Side Control Console and Panel

Remove and Install Left-Side Control Console and Panel

Group 07: Fenders 5415 Narrow

Remove and Install Fenders

Group 10: ROLL-GARD®

Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company

Group 11: ROLL-GARD 5415 NarrowROLL-GARD is a trademark of Deere & Company.

Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.

Group 12: Rear Bar 5415 Narrow

Remove and Install Rear Bar

Section 210: Operational Checkout Procedures

Group 10: Operational Checkout Procedures

Operational Checkout Procedure Information

Engine Oil Level and Condition Check

Coolant Level and Condition Check

Transmission and Hydraulic Oil Check

Fan and Serpentine Belt Check

Fuel System Check

Water Separator Bowl

Cleaning Water Separator

Air Intake System Check

Air Pre-Cleaner

Air Pre-Cleaner Components

Electrical System Check

Hydraulic System Check

MFWD Oil Check

Indicator Lamps Check

Engine Start Check

Transmission Neutral Start Check

PTO Neutral Start Check

Engine Fast and Slow Idle Operation

Power Steering Check

Differential Lock Check

PTO Engagement Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

MFWD Drive Check

Brake Check

Rockshaft Check

Selective Control Valve Check

Park Brake Check 5415 Narrow

Rockshaft Check 5415 Narrow

Selective Control Valve Check 5415 Narrow

Section 220: Engine Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Engine External Components—Left-Hand Side

Engine External Components—Right-Hand Side

Group 10: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation

Engine Lubrication System Operation—Continued

Engine Cooling System Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Engine Turns Over but Will Not Start or Starts Hard

Engine Runs Irregularly or Stalls Frequently

Engine Runs Rough

Engine Has Low Power

Engine Smokes—Black or Grey

Engine Smokes Excessively—White

Engine Uses Excess Fuel

Engine has Excess Noise or Vibration

Engine Uses Excess Oil or Smokes Blue

Engine has Low Oil Pressure

Engine Coolant Operating Temperature Incorrect

Oil In Coolant or Coolant in Oil

Radiator Bubble Test

Cooling System Test

Radiator Cap Pressure Test

Engine Oil Pressure Test

Cylinder Compression Pressure Test

Fuel Shut-Off Solenoid Check

Throttle Lever Adjustment

Slow Idle Adjustment

Fast Idle Adjustment

Injection Pump Timing Adjustment

Check and Adjust Valve Clearance

Turbocharger Boost Pressure Test 5715-5715HC

Bleed Fuel System

Section 230: Fuel/Air Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components—5415 SN( — 004530), 5615 SN( — 003762), 5715 SN( — 007558)

Fuel System Components—5415 SN(004531 — ), 5615 SN(003763 — ), 5715 SN(007559 — )

Fuel System Components—5415 Narrow

Air Intake System Components—Without Turbocharger

Air Intake System Components—With Turbocharger

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation

Fuel System Operation—5415 Narrow

Fuel Filter/Priming Pump Operation

Fuel Injection Nozzle Operation

Air Intake System Operation—Without Turbocharger

Air Intake System Operation—With Turbocharger

Turbocharger Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical System Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Engine Electrical Components - 4 Cylinder

Dash Electrical Components

Machine Electrical Components

Machine Electrical Components 5415 Narrow

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses

Relays

Starting System Operation—Normal

Starting System Operation—Bypass Attempt

Manifold Heater System Operation

Charging System Operation

Lighting System Operation—Turn Signals

Lighting System Operation—Warning Lights

Lighting System Operation—Tail Lights

Lighting System Operation—Headlights and Instrument Lights

Instrument Panel System Operation—Tachometer

Instrument Panel System Operation—Fuel Gauge

Instrument Panel System Operation—Temperature Gauge

Instrument Panel System Operation—Hourmeter

PTO Warning System Operation

Air Filter Restriction Indicator Operation

Rear Work Light Operation

Optional Horn Operation

Accessory Relay and Trailer Connector Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Wire Color Chart

Starting System Test Points—Normal Operation

Starting System Test Points—Bypass Attempt

Air Intake Heater Test Points

Charging System Test Points

Lighting System Test Points—Turn Signals

Lighting System Test Points—Warning Lights

Lighting System Test Points—Rear Work Light

Lighting System Test Points—Tail Lights

Lighting System Test Points—Headlights and Instrument Lights

Instrument Panel System Test Points—Tachometer/Hour Meter

Instrument Panel System Test Points—Fuel Gauge

PTO Warning System Test Points

Air Filter Restriction Test Points

Optional Horn Test Points

Accessory Relay and Trailer Connector Test Points

Battery Voltage and Specific Gravity Tests

Charge Battery

Battery Load Test

Starter Amp Draw/RPM Test

Starter No-Load Amp Draw/RPM Test

Alternator/Regulator Test

Starter Solenoid Test

Starter Relay Test

Key Switch Test

Plug-In Relay Test

Diode Pack Test

Fuse Test

Neutral Start Switch Test

PTO Switch Test

PTO Seat Switch Test

Light Switch Test

Turn Signal Controller Test

Fuel Shut-Off Solenoid Test

Group 20: Wiring Schematics

Schematic Information

Component Identification Table

Legend for Electrical Schematic

Section 250: Power Train Operation, Tests and Adjustments

Group 05: Component Location—Collar Shift/SyncShuttle™ Transmission

Component Location Information

Power Train Components—Range Shift Lever at Right Side5415 (MFWD), 5615 and 5715 Tractors: SN( -003591)5415 (2WD) Tractor: SN( -003591) and SN(004531- )

Power Train Components—Range Shift Lever at Left Side5415 (MFWD), 5617 and 5715 Tractors: SN(003592- )5415 (2WD) Tractor: SN(003592-004530)

Clutch Components—CollarShift and SyncShuttle™ Transmissions

Transmission Components—CollarShift

Transmission Components—SyncShuttle™

Final Drive Components

Final Drive Components—High Clearance Tractors

Park Brake Components—5415 Narrow

Rear 540 PTO Components—CollarShift

Rear 540 PTO Components—Syncshuttle™

Group 10: Theory of Operation—Collar Shift/SyncShuttle™ Transmission

Theory of Operation Information

Clutch Operation—CollarShift and SyncShuttle™ Transmissions

Transmission Lubrication System

CollarShift Transmission—Gear Shift Power Flow

SyncShuttle™ Transmission—Gear Shift Power Flow

SyncShuttle™ Transmission Synchronizer Operation—Reverse and 2nd Gear (Disk-and-Plate Type Synchronizer)

SyncShuttle™ Transmission Synchronizer Operation—1st and 3rd Gear (Cone-Type Synchronizer)

CollarShift Transmission—Range Shift Power Flow

Rear PTO Operation—CollarShift Transmission

Rear PTO Operation—CollarShift Transmission

Rear 540 PTO Operation—SyncShuttle™ Transmission

Rear 540 PTO Operation—SyncShuttle™ Transmission

Differential Power Flow

Differential Power Flow

High Clearance Axle Differential Power Flow

High Clearance Axle Differential Power Flow

Differential Lock Operation

Differential Lock Operation

Final Drive Operation

Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation

Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation

Park Brake Operation–5415 Narrow

Group 15: Diagnosis, Tests and Adjustments—CS/SS Transmission

Diagnostic Information

Isolate the Problem Area

Traction Clutch Slips

Traction Clutch Dragging

Traction Clutch Does Not Engage

Traction Clutch Grabs

Traction Clutch Squeaks

Traction Clutch Does Not Release

Traction Clutch Chatters

Traction Clutch Rattles

Traction Clutch Engagement Is Noisy

Excessive Vibration in Traction Clutch

Clutch Pedal Does Not Return

Clutch Pedal Loose

Clutch Pedal Pulsates

Jerky or Rough Transmission of Power

Low Transmission Oil Level (Excessive Oil Leakage)

Gears Clash, Shift Hard, or Will Not Engage

Two Speeds Engage Together

Transmission Will Not Stay in Gear

Transmission Noisy

PTO Noisy

PTO Hard to Engage

PTO Will Not Operate

PTO Will Not Stay Engaged

Excessive Differential Noise

Differential Does Not Work

No Differential Lock

Differential Chatters

Axle Noise

Axle Shaft Will Not Turn

MFWD Lever Is Hard to Engage

MFWD Lever Will Not Stay in ON Position

Noisy Front Wheel Drive Operation

Check and Adjust Clutch Pedal Free Play–CollarShift and SyncShuttle™ Transmissions

PTO Clutch Lever Adjustment

Section 260: Steering and Brake Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Steering System Components - 5415

Steering System Components —5415 Narrow

Steering System Components - 5615 and 5715-5715HC

Brake System Components

Brake System Components–5415 Narrow

Group 10: Theory of Operation

Theory of Operation Information

Steering System Operation - 5415

Steering System Operation - 5615 and 5715-5715HC

Steering Valve Operation—Neutral and Manual Turning

Steering Valve Operation—Power Turning

Brake System Operation

Brake Valve Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Isolate the Problem—Steering System

Steering Sluggish or Loss of Steering

Isolate the Problem—Brakes

Excessive Brake Pedal Leak-Down

Excessive Brake Chatter

Steering Pump Flow Test

Steering Valve Relief Test

Steering Cylinder Leakage Test

Steering Valve Leakage Test

Toe-In Check —2WD Axle

Toe-In Adjustment —2WD Axle

Toe-In Adjustment —2WD Axle (5415N)

Toe-In Adjustment —2WD Axle (High Clearance Tractors)

Toe-In Check and Adjustment—Early MFWD Axle

MFWD Steering Stop Adjustment

Brake Pedal Adjustment

Bleed Brake System

Park Brake Band Adjustment—5415 Narrow

Park Brake Linkage Adjustment—5415 Narrow

Section 270: Hydraulic System Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components–5415

Hydraulic System Components–5415 Narrow

Hydraulic System Components–5615 and 5715

Selective Control Valve Components

Selective Control Valve Components–5415 Narrow

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic System Operation

Hydraulic System Operation–5415 Narrow

Hydraulic Filter Operation

Hydraulic Pump Operation

Rockshaft Control Valve Operation—Two Flow Regulator Valves

Rockshaft Control Valve Operation—Neutral Position

Rockshaft Control Valve Operation—Raise Position

Rockshaft Control Valve Operation—Lower Position

Surge Relief Valve Operation

Rate-of-Drop Valve Operation—Full Open

Rate-of-Drop Valve Operation—Full Closed

Rockshaft Draft-Sensing Operation

SCV Operation (Neutral Position)

Selective Control Valve Operation—Extend and Retract Positions

Selective Control Valve Operation—Boom Spool Float Position

Selective Control Valve Operation—Bucket Spool Regenerative Position

Double-Acting Sleeve Coupler Operation

Selective Control Valve Operation—Neutral Position 5415 Narrow

Selective Control Valve Operation—Extend and Retract Positions 5415 Narrow

Selective Control Valve Operation—Boom Spool Float Position 5415 Narrow

Double-Acting Sleeve Coupler Operation–5415 Narrow

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

Hydraulic Oil Warm-Up Procedure

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down

SCV Does Not Return to Neutral Position-Single (Third) SCV

SCV Does Not Return to Neutral to Neutral Position-Dual SCV

SCV Does Not Remain in Detent Position-Dual SCV

Remote Cylinder Does Not Extend or Retract

Remote Cylinder Settles Under Load

Remote Cylinder Operates Too Fast or Too Slow

Group 16: Hydraulic Tests—Without SCV

Hydraulic System Tests—Without SCV

Pump Flow Test—Without SCV

Main Relief Valve Test—Without SCV

Group 17: Hydraulic Tests—With SCV

Hydraulic System Tests—With SCV

Hydraulic System Tests 5415 Narrow

Pump Flow Test—With SCV

Main Relief Valve Test—With SCV

SCV Leakage Test

Group 18: Hydraulic Tests—All

Rockshaft Leakage Test

Rockshaft Leakage Test 5415 Narrow

Rockshaft Lift Cycle Test

Group 19: Adjustments

Rockshaft Sensing Lever Friction Adjustment

Rockshaft Position-Sensing Feedback Linkage Adjustment

Rockshaft Draft-Sensing Feedback Linkage Adjustment

Main Relief Valve Adjustment

Relief Valve Adjustment 5415 Narrow

Group 20: Hydraulic Schematics

Hydraulic Circuit Symbols

Hydraulic Circuit Symbols - Continued

Legend for Hydraulic Schematic—Without Selective Control Valves

Legend for Hydraulic Schematic—With Selective Control Valves

Hydraulic Schematic 5415 Narrow

Power Beyond Hydraulic Schematic

Section 290: Dealer Fabricated Tools

Group 00: Dealer Fabricated Tools

PTO Clutch Finger Height Gauge

Traction Clutch Finger Height Gauge

Traction Clutch Finger Height Adjustment Tool

DFLV1A Final Drive Turning Tool

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