John Deere Tractors 5415, 5415N; 5415H, 5615, 5615HC; 5715, 5715HC Diagnostic and Repair Service Manual - TM6019
Catalog:
Price: US$ 59.00
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, and 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.
tm6019 - 5415, 5415 Narrow, 5415 Orchard, 5615, 5715 and 5715HC Tractors Technical Manual.pdf
tm6019 - 5415, 5415 Narrow, 5415 Orchard, 5615, 5715 and 5715HC Tractors Technical Manual.epub
Total Pages: 1,484 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
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
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
John Deere Tractors 5415, 5415N; 5415H, 5615, 5615HC; 5715, 5715HC Diagnostic and Repair Service Manual - TM6019
