John Deere Tractors Models 6105R, 6115R, 6125R, 6130R Repair Service Manual (TM404519)

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John Deere Tractors Models 6105R, 6115R, 6125R, 6130R Repair Service Manual (TM404519)

tm404519 - 6105R to 6130R Tractors Repair -: (Worldwide Edition) Technical Manual.pdf

Complete Repair Service Technical Manual for John Deere Tractors 6105R, 6115R, 6125R, 6130R (Worldwide), with all the shop information to maintain, service, repair like professional mechanics.

John Deere Tractors Models 6105R, 6115R, 6125R, 6130R workshop technical manual (repair) 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.
* 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.

Total Pages: 1,891 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Safety
      Safety Measures
   General
      General Information - Specifications
      General Information - Tests and Adjustments
      General Information - Predelivery Inspection
   Engine
      Engine – Removal and Installation of Components
   Fuel, Air-Intake, Cooling, and Exhaust System
      Fuel System
      Air Intake System
      Cooling System
      Exhaust System
   Electrical System
      Electrical System - Connectors
      Electrical System - Charging Circuit
      Electrical System - Starter Circuit
      Electrical System - Headlights
   Electronic Control Units
      Removal and Installation of Electronic Control Units
      Terminating Resistors, Removal and Installation
   Drive Train (without Transmission)
      Drive Train (without Transmission) - Removal and Installation of Components
      Drive Train (without Transmission) - U.J. Shafts and Torsion Dampers
      Drive Train (without Transmission) - Mechanical Front-Wheel Drive
      Drive Train (without Transmission) - Differential
      Drive Train (without Transmission) - Hydraulic Pump Drive
      Drive Train (without Transmission) - Final Drives
      Drive Train (without Transmission) - Rear PTO Options
      Drive Train (without Transmission) - Front PTO for European Tractors
      Drive Train (without Transmission) - Front Implement Drive
   AutoPowr™/IVT™ Transmission
      AutoPowr™/IVT™ Transmission - Removal and Installation of Components
      AutoPowr™/IVT™ Transmission (Repair, Removal and Installation)
   PowrQuad™ Transmission
      PowrQuad™ Transmission - Removal and Installation of Components
      PowrQuad™ Transmission - Transmission Shift Unit
      PowrQuad™ Transmission - PowrQuad™ Module
      PowrQuad™ Transmission - Creeper Transmission
      PowrQuad™ Transmission - Option Transmission
      PowrQuad™ Transmission - Range Transmission
   Steering
      Steering - Hydrostatic Steering
      Steering - AutoTrac™
   Brakes
      Brakes - Brake Valve
      Brakes - Rear Brakes
      Brakes - Hydraulic Trailer Brake
      Brakes - Air Brake System
      Brakes - Emergency Brake System
   Hydraulic System
      Hydraulic System - General Information
      Hydraulic System - Controls
      Hydraulic System - Oil Filter, Additional Oil Reservoir, Charge Pump, and Hydraulic Pump
      Hydraulic System - Priority 1 to 3 Control Blocks
      Hydraulic System - Rear Hitch
      Hydraulic System - Front Hitch
      Hydraulic System - Selective Control Valves (SCVs) and Couplers
      Hydraulic System - Independent Control Valves (ICVs)
   Machine-Specific Systems
      Machine-Specific Systems - Removal and Installation of Components
      Machine-Specific Systems - Main Frame
      Machine-Specific Systems - Front Wheels, Rear Wheels and Fenders
      Machine-Specific Systems – Trailer Hitch and Swinging Drawbar
      Machine-Specific Systems - Hydraul. Wagon Hitch
   Suspension Systems
      Suspension Systems - Suspended Front-Wheel Drive Axle
      Suspension Systems - Cab Suspension
   Operator's Cab
      Operator's Cab - Installation and Removal of Components
      Operator's Cab - Operation and Control Devices
      Operator's Cab - Air-Conditioning System
      Operator's Cab - ClimaTrak™
      Operator's Cab - Seats
      Operator's Cab - Operator's Cab
   Special Tools
      General Information

 

tm404519 - 6105R to 6130R Tractors Repair -: (Worldwide Edition)

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Measures

General Information - Safety - Summary of References

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Prevent Machine Runaway

Operating the Tractor Safely

Operating the Loader Tractor Safely

Passenger Seat

Use Safety Lights and Devices

Towing Trailers/Implements Safely (Mass)

Use Caution On Slopes and Uneven Terrain

Freeing a Mired Machine

Avoid Backover Accidents

Handle Fluids Safely—Avoid Fires

Handling Batteries Safely

Prepare for Emergencies

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Avoid Contact with Agricultural Chemicals

Handle Agricultural Chemicals Safely

Stay Clear of Rotating Drivelines

Wear Protective Clothing

Protect Against Noise

Practice Safe Maintenance

Avoid Hot Exhaust

Exhaust Filter Cleaning

Clean Exhaust Filter Safely

Read Operator Manuals for ISOBUS Implements

Use Steps and Handholds Correctly

Use Seat Belt Properly

Park Machine Safely

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Support Machine Properly

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Service Accumulator Systems Safely

Service Tires Safely

Use Proper Tools

Service Front-Wheel Drive Tractor Safely

Avoid Eye Contact With Radar

Keep ROPS Installed Properly

Replace Safety Signs

Replace Safety Signs

Dispose of Waste Properly

Live With Safety

Safety Measures on Electronic Control Units

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Safety Instructions for Replacing a Halogen Bulb

Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units

Section 10: General Information

Group 05: General Information - Specifications

Specifications - Summary of References

Engine Specifications

PTO Power Output

Capacities

Air Intake System

Electrical System

Hydraulic System with Axial Piston Pump (PFC System)

Clutch Operation

PowrQuad PLUS™ Transmission

AutoQuad PLUS™ Transmission

Rear PTO

Front PTO

Differential

Differential Lock

Final Drives

Front-Wheel Drive

FWD Axle with TLS

Cab Suspension

Hydraulic Brakes

Auxiliary Brake

Park Lock

Hitch

Immobilizer

Front Hitch

Ground Travel Speeds

Front and Rear Wheels

Dimensions and Weights

Handling and Storing Diesel Fuel

Diesel Fuel

Minimizing the Effect of Cold Weather on Diesel Engines

Biodiesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Break-In Oil

John Deere Break-In™ Plus Engine Oil

Transmission and Hydraulic Oil

Oil for Front-Wheel Drive Axle

Heavy Duty Diesel Engine Coolant

Supplemental Coolant Additives

Grease

Oil Filters

Mixing of Lubricants

Lubricant Storage

Operating in Warm Temperature Climates

Alternative and Synthetic Lubricants

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Hydraulic system inch fitting torques

Hydraulic system metric fitting torques

Product Identification and Component Serial Number Plate

Plate for Product Identification Number

Engine Serial Number

Transmission Serial Number

Front-Wheel Drive Serial Number

Operator's Cab Serial Number

Operator's seat serial number

Subassembly Serial Numbers

Group 10: General Information - Tests and Adjustments

Tests and Adjustments - Summary of References

Using High-Pressure Washers

Preliminary Engine Test

Visual Inspection of the Fuel System

Check the Fuel Filter

Checking the Function of the Fuel Transfer Pump

Bleeding the Fuel System

Installation and Removal of the Primary Air Cleaner Element

Check the Secondary (Safety) Element

Drain Coolant

Check Transmission/Hydraulic System Oil Level

Group 15: General Information - Predelivery Inspection

Predelivery Inspection

Section 20: Engine

Group 00: Engine – Removal and Installation of Components

Engine - Removal and Installation of Components, Summary of References

Engine - Removal and Installation of Components, Special Tools

Engine - Removal and Installation of Components, Repair Specifications

Removing the Engine, Preliminary Work

Engine Removal

Installing the engine

Installing the Engine, Additional Work

Engine Mounting

Replacing the Engine Mountings, Preliminary Work

Replacing the front engine mountings

Replacing the Rear Engine Mountings

Replacing the engine mounting, Further work

Section 30: Fuel, Air-Intake, Cooling and Exhaust Systems

Group 10: Fuel System

Fuel System - Summary of References

Fuel Tank, Removal and Installation

Fuel Level Sensor, Removal and Installation

Bleeding the Fuel System

Group 15: Air Intake System

Air Intake System - Summary of References

B02 - Sensor for Air Cleaner Restriction Warning Light, Removal and Installation

Group 20: Cooling System

Cooling System - Summary of References

Opening Engine Hood

Engine Hood Removal and Installation

Cooler Package Removal and Installation

Charge Air Cooler Removal and Installation

Radiator Removal and Installation

Relieving Drive Belt Tension

Replace the Drive Belt

Routing of Drive Belt

Automatic Belt Tensioner, Removal and Installation

Group 30: Exhaust System

Exhaust System - Summary of References

Special Tools - Summary of References

Exhaust Filter — Handling and Disposal of Ash from the Diesel Particulate Filter

Emission Control System, Important Instructions

Exhaust System to Top Right Removal and Installation

Exhaust Filter - Adjustment

Section 40: Electrical System

Group 05: Electrical System - Connectors

Electrical System - Connectors, Summary of References

Connectors—Special Tools, Summary of References

Installation of the Repair Cable Kit (Smoke and Heat Exhaust System)

General

Using high-pressure washers

Strip Wire Ends

Install Electrical Terminal

WEATHER PACK Connectors

METRI PACK Connector with Terminal Lock at the Rear

METRI PACK Connector with Terminal Lock at the Front

METRI PACK Connectors

Connectors for Electronic Control Units

Connector

CRIMP SNAP IN Connectors

KOSTAL Connectors

DEUTSCH Connectors

Individual Terminals

Bosch™ Connectors

Repair DEUTSCH™ Implement Connectors

Repair Molex™ Connectors

Repair SUMITOMO™ Connectors

Repair YAZAKI™ Connectors

Group 10: Electrical System - Charging Circuit

Electrical System - Charging Circuit, Summary of References

Electrical System - Disconnect the Electrical Circuit

Electrical System - Remove and Install Battery

Electrical System - Alternator Removal and Installation

Group 15: Electrical System - Starter Motor Circuit

Electrical System - Starter Circuit, Summary of References

Electrical System - Starter Removal and Installation

Group 20: Electrical System - Headlights

Electrical System - Lights, Summary of References

General information

Electrical System - Setting Lights

Adjusting Lights on the Cab Frame

Safety Instructions for Replacing a Halogen Bulb

Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units

Electrical System - Worklights and Beacon Warning Light, Removal and Installation

Section 45: Electronic Control Units

Group 05: Removal and Installation of Electronic Control Units

Electronic Control Units - Summary of References

Instructions when Replacing a Control Unit

Control Units Location

Roof Control Unit - Removal and Installation

Front Chassis Control Unit (M50) - Removal and Installation

Front Chassis Control Unit (M400) - Removal and Installation

Cab Switch Module Control Unit - Removal and Installation

Engine Control Unit - Removal and Installation

Immobilizer Control Unit - Removal and Installation

Cab Control Unit - Removal and Installation

Air-Conditioning or ClimaTrak™ Control Unit - Removal and Installation

Steering Control Unit (AutoTrac™) - Removal and Installation

Instrument Unit - Removal and Installation

CommandCenter™ Control Unit - Removal and Installation

Rear Chassis Control Unit - Removal and Installation

Control Unit for Power-Assisted Rear PTO Shifting (PAPTOS) - Removal and Installation

Transmission Control Unit (AutoPowr™/IVT™) - Removal and Installation

Group 10: Terminating Resistors - Removal and Installation

Terminating Resistors - Summary of References

A53 - CAN-BUS Terminating Resistor (CAN-BUS - Implement)

A83 - CAN BUS Terminating Resistor (Vehicle CAN BUS (500 kBd))

R021 - CAN BUS Terminating Resistor (CAN BUS Vehicle (500 kBd))

A84 - CAN BUS Terminating Resistor (Vehicle CAN BUS (500 kBd))

R020 - CAN BUS Terminating Resistor (CAN BUS Vehicle (500 kBd))

A131 - CAN BUS Terminating Resistor (Engine CAN Bus)

Section 50A: Drive Train (without Transmission)

Group 00: Drive Train (without Transmission) - Removal and Installation of Components

Drive Train (without Transmission) - Removal and Installation of Components, Summary of References

Drive Systems - Special Tools

Drive Train (without Transmission) - Repair Specifications

Draining Transmission/Hydraulic Oil

Filling System with Transmission/Hydraulic Oil

Remove the Final Drives

Install the Final Drives

Rear PTO Removal

Install the Rear PTO

Removing the Front PTO

Install the Front PTO

Group 10: Drive Train (without Transmission) - Universal-Jointed Shafts and Torsion Dampers

Drive Train (without Transmission) - U.J. Shafts and Torsion Dampers, Summary of References

U-Jointed Shafts and Torsion Dampers - Repair Specifications

U.J. Shafts and Torsion Dampers - Removing the U.J. Shaft (MFWD)

Universal-joint shafts and torsion dampers - Reconditioning the u.j. shaft (MFWD)

U.J. Shafts and Torsion Dampers - Installing the U.J. Shaft (MFWD)

U.J. Shafts and Torsion Dampers - Remove the Engine U.J. Shaft

Universal-Joint Shafts and Torsion Dampers - Installing the Engine Universal-Joint shafts

Universal-Joint Shafts and Torsion Dampers - Removing the Torsion Dampers

Universal-Joint Shafts and Torsion Dampers - Replacing the Torsion Damper Bearing

Universal-Jointed Shafts and Torsion Dampers - Installing the Torsion Damper

Group 15: Drivetrain (without Transmission) - Mechanical Front-Wheel Drive

Drive Train (without Transmission) - Mechanical Front-Wheel Drive, Summary of References

Mechanical Front-Wheel Drive - Special Tools

Mechanical Front-Wheel Drive - Repair Specifications

Mechanical Front-Wheel Drive - Replace the Front-Wheel Drive Axle Speed Sensor

Mechanical Front-Wheel Drive - Reconditioning the MFWD Solenoid Valve

Mechanical Front-Wheel Drive - Sectional View

Mechanical Front Wheel Drive - Exploded View

Removing the Mechanical Front-Wheel Drive

Mechanical Front-Wheel Drive - Removing the FWD Clutch (PowrQuad™ Transmission)

Mechanical Front-Wheel Drive - Remove the Front-Wheel Drive Clutch (AutoPowr™/IVT™ Transmission)

Mechanical Front-Wheel Drive - Repair the Front-Wheel Drive Clutch

Mechanical Front-Wheel Drive - Install the Front-Wheel Drive Clutch (PowrQuad™ Transmission)

Mechanical Front-Wheel Drive - Install the Front-Wheel Drive Clutch (AutoPowr™/IVT™ Transmission)

Mechanical front-wheel drive - Adjusting axial play of output driveshaft

Installing the Mechanical Front-Wheel Drive

Group 20: Drive Train (without Transmission) - Differential

Drive Train (without Transmission) - Differential, Summary of References

Differential - Special Tools

Differential - Repair Specifications

Differential - Handling KJD10672 - Lifting tool for differential

Differential - Replacing the Wheel Speed Sensor

Differential - Replacing Solenoid Valve for Differential Lock

Differential - Sectional View

Differential - Exploded View

Remove the Differential

Recondition the Differential

Install Differential

Differential - Adjusting the Tapered Roller Bearing and Backlash

Group 25: Drive Train (without Transmission) - Hydraulic Pump Drive

Drive Train (without Transmission) - Hydraulic Pump Drive, Summary of References

Hydraulic Pump Drive - Special Tools

Hydraulic Pump Drive - Repair Specifications

Hydraulic Pump Drive - Sectional View

Hydraulic Pump Drive - Exploded View

Removing the hydraulic pump drive

Installing the Hydraulic Pump Drive

Adjusting the Hydraulic Pump Drive

Hydraulic Pump Drive - Check and Adjust the Backlash of the Pump Drive Pinion

Group 30: Drive Train (without Transmission) - Final Drives

Drive Train (without Transmission) - Final Drives, Summary of References

Final Drives - Special Tools

Final Drives - Repair Specifications

Final Drives - Sectional View

Exploded View of Final Drives

Disassemble the Final Drives

Reconditioning the Final Drives

Assemble the Final Drives

Final Drives - Checking and Adjusting Rolling Drag Torque

Group 35: Drive Train (without Transmission) - Rear PTO Options

Drive Train (without Transmission) - Rear PTO Options, Summary of References

Rear PTO Options - Special Tools

Rear PTO Options - Repair Specifications

Rear PTO Options - Replacing the Output Shaft Seal Ring

Rear PTOs - Sectional View

Rear PTO Options - Exploded View

Rear PTO Options - Removing the PTO Clutch

Rear PTO Options - Reconditioning the PTO Clutch

Rear PTOs - Reconditioning the PTO brake

Rear PTO Options - Installing the PTO Clutch

Rear PTO Options - Removing the PTO Drive Train

Rear PTO Options - Reconditioning the Output Shaft

Rear PTO Options - Reconditioning the Countershaft

Rear PTOs - Reconditioning the PTO shifter

Rear PTO Options - Install the PTO Drivetrain

Rear PTO Options - Adjusting the Tapered Roller Bearing of the Countershaft

Rear PTO Options - Adjusting the Tapered Roller Bearing of the Bearing Support

Rear PTO Options - Reconditioning the PTO Shaft Spline Identifier

Rear PTO Options - Replacing Y81 Proportional Solenoid Valve for Rear PTO

Rear PTOs - Replacing B06 sensor for rear PTO speed

Rear PTOs - Reconditioning the oil sight glass

Group 40: Drive Train (without Transmission) - Front PTO for European Tractors

Drive train (without transmission) - Front PTO, Summary of references

Front PTO - Repair Specifications

Front PTO - Sectional View

Front PTO - Exploded view

Front PTO - Changing the Oil Filter

Disassembling the Front PTO

Assemble Front PTO

Front PTO - Replacing the front PTO speed sensor

Front PTO - Replacing the front PTO proportional solenoid valve

Front PTO - Replacing the Oil Cooler

Group 45: Drive Train (without Transmission) - Front Implement Drive

Drive Systems - Front Implement Drive, Summary of References

Front Implement Drive - General Information

Front Implement Drive - Repair Specifications

Front Implement Drive - Exploded View

Removal of the Front Implement Drive

Reconditioning the Front Implement Drive

Installing the Front Implement Drive

Front Implement Drive - Tightening the Clutch Screws (after 100 Operating Hours)

Section 50B: AutoPowr™/IVT™ Transmission

Group 00: AutoPowr™/IVT™ Transmission - Removal and Installation of Components

AutoPowr™/IVT™ Transmission - Removal and Installation of Components, Summary of References

AutoPowr™/IVT™ Transmission - Special Tools

AutoPowr™/IVT™ Transmission - Repair Specifications

Removal of the AutoPowr™/IVT™ Transmission, Preliminary Work

Removing the AutoPowr™/IVT™ Transmission

Installing the AutoPowr™/IVT™ Transmission

Group 05: AutoPowr™/IVT™ Transmission (Repair, Removal and Installation)

AutoPowr™/IVT™ Transmission (Repair, Removal and Installation)

Section 50C: PowrQuad™ Transmission

Group 00: PowrQuad™ Transmission - Removal and Installation of Components

PowrQuad™ Transmission - Removal and Installation of Components, Summary of References

PowrQuad™ Transmission - Installation and Removal of Components, Special Tools

PowrQuad™ Transmission - Removal and Installation of Components, Repair Specifications

PowrQuad™ Plus Transmission, Removal and Installation

AutoQuad™ Plus Transmission, Removal and Installation

Removing the PowrQuad™ Transmission - Preliminary Work

Removing the PowrQuad™ Transmission

Installing the PowrQuad™ Transmission

Remove the Creeper or Option Transmissions

Install the Creeper or Option Transmissions

Remove the Range Transmission

Install the Range Transmission

Group 10: PowrQuad™ Transmission - Transmission Shift Unit

Transmission Shift Controls, Summary of References

PowrQuad™ Transmission - Checking and Adjusting the Shifter and the Park Lock

PowrQuad™ Transmission - Removing the Shift Unit

PowrQuad Transmission - Reconditioning the Shift Unit

PowrQuad™ Transmission - Installing the Shift Unit

PowrQuad™ Transmission - Reconditioning the Clutch Actuation Mechanism

Group 15: PowrQuad™ Transmission - PowrQuad™ Module

PowrQuad™ Transmission - PowrQuad™ Module, Summary of References

PowrQuad™ Transmission - Special Tools, Summary of References

PowrQuad™ Transmission - Repair Specifications

PowrQuad™ Transmission - Transmission Components

PowrQuad™ Transmission - Replacing the Temperature Sensor and Pressure Switches

PowrQuad™ Transmission - Remove and Install the Oil Filter Housing

PowrQuad™ Transmission - Replacing the Oil Filter Housing

PowrQuad™ Transmission - Remove and Install the Front Valve Housing

PowrQuad™ Transmission - Remove and Install the Valves in the Front Valve Housing

PowrQuad™ Transmission - Removing and Installing the Front Transmission Cover

PowrQuad™ Transmission - Removing and Installing the Valves in the Front Transmission Cover

PowrQuad™ Transmission - Remove and Install the Shift Valve Housing

PowrQuad™ Transmission - Remove and Install Valves in Shift Valve Housing

PowrQuad™ Transmission - Remove the Transmission Oil Pump

PowrQuad™ Transmission - Repair the Transmission Oil Pump

PowrQuad™ Transmission - Installing the Transmission Oil Pump

PowrQuad™ Transmission - Removing the Gear-Shift Planetary Drive.

PowrQuad™ Transmission - Repair the Gear-Shift Planetary Drive

PowrQuad™ Transmission - Install the Gear-Shift Planetary Drive

PowrQuad™ Transmission - Removing the B1 Brake Housing

PowrQuad™ Transmission - Reconditioning the B1 Brake

PowrQuad™ Transmission - Installing the B1 Brake Housing

PowrQuad™ Transmission - Removing the B2-B3 Brake Housing

PowrQuad™ Transmission - Reconditioning the B2 Brake

PowrQuad™ Transmission - Reconditioning the B3 Brake

PowrQuad™ Transmission - Installing the B2-B3 Brake Housing

PowrQuad™ Transmission - Removing the C4 Clutch

PowrQuad™ Transmission - Recondition the C4 Clutch

PowrQuad™ Transmission - Install the C4 Clutch

PowrQuad™ Transmission - Removing the Reverse Brake

PowrQuad™ Transmission - Repair the Reverse Brake

PowrQuad™ Transmission - Installing the Reverse Brake

PowrQuad™ Transmission - Removing Forward Clutch with Planetary Drive (Travel Direction)

PowrQuad™ Transmission - Recondition the Forward Clutch with Planetary Drive (Travel Direction)

PowrQuad™ Transmission - Installing Forward Clutch with Planetary Drive (Travel Direction)

PowrQuad™ Transmission - Replacing Clutch Carriers for C4 Clutch and Forward Clutch

PowrQuad™ Transmission - Replace the Transmission Output Shaft and Rear PTO Drive Shaft

Group 20: PowrQuad™ Transmission - Creeper Transmission

PowrQuad™ Transmission - Reconditioning the Creeper Transmission, Summary of References

PowrQuad™ Transmission - Creeper Transmission - Repair Specifications

PowrQuad™ Transmission - Reconditioning the Creeper Transmission

PowrQuad™ Transmission - Creeper Transmission - Reconditioning the Shift Cover

Group 25: PowrQuad™ Transmission - Option Transmission

PowrQuad™ Transmission - Reconditioning the Option Transmission, Summary of References

PowrQuad™ Transmission - Option Transmission - Repair Specifications

PowrQuad™ Transmission - Reconditioning the Option Transmission

Group 30: PowrQuad™ Transmission - Range Transmission

PowrQuad™ Transmission - Range Transmission - Reconditioning, Summary of References

PowrQuad™ Transmission - Repair Specifications

PowrQuad™ Transmission - Range Transmission - Sectional View

PowrQuad™ Transmission - Reconditioning the Range Transmission

PowrQuad™ Transmission - Assembling the Range Transmission

PowrQuad™ Transmission - Reconditioning the Shift Cover

PowrQuad™ Transmission - B104 - Replacing the Transmission Output Speed Sensor

Section 60A: Steering system

Group 10: Steering - Hydrostatic Steering

Steering - Hydrostatic Steering, Summary of References

Hydrostatic Steering - Special Tools, Summary of References

Hydrostatic Steering - Repair Specifications

Hydrostatic Steering - Disconnect/Connect the Steering or Brake Hoses

Hydrostatic Steering - Exploded View

Hydrostatic Steering - Removal and Installation of the Gas-Filled Cylinder

Hydrostatic Steering - Removing the Steering Column

Hydrostatic Steering - Removing the Steering Valve

Hydrostatic Steering - Installing the Steering Valve

Hydrostatic Steering - Install the Steering Column

Group 15: Steering - AutoTrac™

Steering System - AutoTrac™, Summary of References

AutoTrac™ - Repair Specifications

AutoTrac™ - Exploded View

AutoTrac™ - Replacing the Steering Control Valve

AutoTrac™ - Y114-1 - Solenoid Valve for Steering Control Valve (Enable Valve)

AutoTrac™ - Y114-2 - Solenoid Valve for Steering Control Valve (Left Turn)

AutoTrac™ - Y114-3 - Solenoid Valve for Steering Control Valve (Right Turn)

AutoTrac™ - B138 - Replace the Steering Wheel Position Sensor

AutoTrac™ B139 - Removal and Installation of the Steering Angle Sensor

Section 60B: Brakes

Group 10: Brakes - Brake Valve

Brakes - Brake Valve, Summary of References

Brake Valve - Special Tools, Summary of References

Brake Valve - Repair Specifications

Brake Valve - Disconnecting/Connecting Steering or Brake Hoses

Brake Valve - Changing the Accumulator

Brake Valve - Reconditioning the Guide and Piston

Brake Valve - Exploded View

Remove Brake Valve (Power Fill Brakes)

Reconditioning the Power Brake Valve

Install the Power Brake Valve

Remove Power-Fill Brake Valve with MFWD and Disk Brake

Reconditioning the Power Brake Valve with MFWD and Multi-Disk Brake

Installing the Power-Fill Brake Valve with MFWD and Disk Brake

Group 15: Brakes - Rear Brakes

Brakes - Rear Brakes, Summary of References

Rear Brakes - Special Tools, Summary of References

Rear Brakes - Repair Specifications

Rear Brakes - Exploded View

Remove the Rear Brakes

Install the Rear Brakes

Rear Brakes - Replacing the Delay Valve with Shuttle Valve

Rear Brakes - Check Brake Pistons for Return Movement and Leakage

Group 20: Brakes - Hydraulic Trailer Brake

Brakes - Hydraulic Trailer Brake, Summary of References

Hydraulic Trailer Brake - Repair Specifications

Hydraulic Trailer Brake - Repair Instructions

Hydraulic Trailer Brake - Changing the Trailer Brake Valve

Hydraulic Trailer Brake - Change the Coupler

Group 25: Brakes - Air Brake System

Brakes - Air-brake system, Summary of references

Air Brake System - Special Tools, Summary of References

Air-Brake System - Repair Specifications

Air-Brake System - Safety Instructions

Air Brake System - Installing the Compressed-Air Hoses

Air-brake system - Replacing the compressor

Air Brake System - Reconditioning the Compressor

Air-Brake System - Replacing the Compressed-Air Tank

Air-Brake System - Replacing the Trailer Control Valve (for Dual-Line Brakes)

Air-brake system - Replacing the trailer control valve (for single-line brakes)

Air Brake System - Change the Coupling Ends

Group 30: Brakes - Emergency Brake System

Brakes - Auxiliary Brake, Summary of References

Emergency Brake System - Repair Specifications

Emergency Brake - Exploded View

Remove the Emergency Brake

Install the Emergency Brake

Emergency Brake - Replace the Brake Cable

Section 70: Hydraulic System

Group 05: Hydraulic System - General Information

Hydraulic System - General Information, Summary of References

Hydraulic System - General Safety and Repair Information

Group 10: Hydraulic System - Controls

Hydraulic System - Reconditioning the Controls, Summary of References

Repair Specifications

Selective Control Valves (M-SCVs) - Remove and Install the Actuating Elements

Selective Control Valves (M-SCVs) - Adjust the Actuating Cable

Remove and Install Multi-Function Lever (on Shift Console) for M-SCVs at Position 3 and 4 (Edition 1)

Adjust the Multi-Function Lever (on Shift Console) for M-SCVs at Position 3 and 4 (Edition 1)

Remove and Install the Multi-Function Lever (on Shift Console) for M-ICVs (Edition 1)

Adjust Multi-Function Lever (on Shift Console) for M-ICVs (Edition 1)

Remove and Install the Multi-Function Lever (on Shift Console) for M-SCVs at Position 3 and 4 (Version 2)

Adjust the Multi-Function Lever (on Shift Console) for M-SCVs at Position 3 and 4 (Edition 2)

Remove and Install the Multi-Function Lever (on Shift Console) for M-ICVs (Edition 2)

Adjust Multi-Function Lever (on Shift Console) for M-ICVs (Edition 2)

Group 15: Hydraulic System - Oil Filter, Additional Oil Reservoir, Charge Pump, and Hydraulic Pump

Hydraulic System - Oil Filter, Additional Oil Reservoir, Charge Pump and Hydraulic Pump, Summary of References

Repair Specifications

Removal and Installation of the Hydraulic Oil Primary Filter

Hydraulic Oil Filter, Reconditioning

Removal and Installation of the Charge Oil Pump

Charge Oil Pump - Checking the Lube Oil Valve

Hydraulic Pump - Oil Reservoir

Hydraulic Pump - Removal and Installation of the Pressure-and-Flow Regulator

Removal and Installation of the Hydraulic Pump

Removal and Installation of the Additional Oil Reservoir

Group 20: Hydraulic System - Priority 1 to 3 Control Blocks

Hydraulic System - Reconditioning the Priority 1 to 3 Control Blocks, Summary of References

Reconditioning the Priority 1 to 3 Control Blocks - Special Tools, Summary of References

Repair Specifications

Removal and Installation of the Priority 1 Control Block

Reconditioning the Priority 1 Control Block

Removal and Installation of the Control Block with/without Priority 2

Reconditioning the Priority 2 Control Block

Reconditioning the Control Block (without Priority 2)

Removal and Installation of the Priority 3 Control Block

Recondition the Priority 3 Control Block

Group 25: Hydraulic System - Rear Hitch

Hydraulic System - Repair the Rear Hitch, Summary of References

Reconditioning the Rear Hitch - Special Tools, Summary of References

Other Material

Repair Specifications

Rear Hitch - Hitch Valve, Removal and Installation of the Stepper Motor

Rear Hitch - Removal and Installation of the Hitch Valve

Rear Hitch - Recondition the Hitch Valve

Rear Hitch - Removal and Installation of the Position Sensor and Toothed Segment

Rear Hitch - Remove and Install Rockshaft Bearing Block

Rear Hitch - Recondition Rockshaft Bearing Block

Rear Hitch - Removal and Installation of the Lift Cylinders

Rear Hitch - Reconditioning the Lift Cylinders

Rear Hitch - Removal and Installation of the Draft Sensors and Draft Link Bearing Pins

Rear Hitch - Hydraulic Draft Link Stabilizer Bars (HSB) - Removal and Installation of the Control Block

Rear Hitch - Hydraulic Draft Link Stabilizer Bars (HSB), Reconditioning the Control Block

Rear Hitch - Remove and Install Hydraulic Draft Link Stabilizer Bars (HSB)

Rear Hitch - Recondition the Hydraulic Draft Link Stabilizer Bars (HSB)

Rear Hitch - Remove and Install the Hydraulic Center Link (HCL)

Rear Hitch - Recondition the Hydraulic Center Link (HCL)

Group 30: Hydraulic System - Front Hitch

Hydraulic System - Reconditioning the Front Hitch - Summary of References

Repair Specifications

Front Hitch - Remove and Install the Lift Cylinders

Front Hitch - Recondition the Lift Cylinders

Front Hitch - Remove and Install Lift Arm

Front Hitch - Remove and Install Quick Couplers

Group 35: Hydraulic System - Selective Control Valves (SCVs) and Couplers

Repair the Selective Control Valves (SCVs) and Couplers - Summary of References

Repair Specifications

Selective Control Valves (E-SCVs) - Removal and Installation of the Stepper Motors

Removing and Installing the Selective Control Valves (SCVs)

Reconditioning the Selective Control Valves (M-SCVs 100)

Reconditioning the Selective Control Valves (M-SCVs 200)

Reconditioning the Selective Control Valves (M-SCVs 300)

Recondition the Selective Control Valves (M-SCVs 350)

Recondition the Selective Control Valves (M-SCVs 450)

Recondition the Selective Control Valves (E-SCVs 300)

Recondition the Selective Control Valves (E-SCVs 350)

Recondition the Selective Control Valves (E-SCVs 450)

Selective Control Valves (SCVs) - Reconditioning the Couplers

Group 40: Hydraulic System - Independent Control Valves (ICVs)

Repair the Independent Control Valves (ICV) - Summary of References

Repair Specifications

Remove and Install the Independent Control Valves (M-ICVs)

Recondition the Independent Control Valves (M-ICVs)

Independent Control Valves (E-ICV) - Removal and Installation of the Stepper Motors

Remove and Install the Independent Control Valves (E-ICVs)

Recondition the Independent Control Valves (E-ICVs)

Section 80A: Machine-Specific Systems

Group 00: Machine-Specific Systems - Removal and Installation of Components

Machine-Specific Systems - Removal and Installation of Components, Summary of References

Machine-Specific Systems - Special Tools

Machine-Specific Systems - Repair Specifications

Remove the Axle, Preliminary Work

Remove Suspended Front-Wheel Drive Axle

Install Suspended Front-Wheel Drive Axle

Remove the Front-Wheel Drive Axle

Installing the Front-Wheel Drive Axle

Remove Front Axle

Install the Front Axle

Install the Axle, Additional Work

Removing the Front Hitch

Installing the Front Hitch

Remove the Front Axle Support, Preliminary Work

Remove the Front Axle Support for Suspended Front-Wheel Drive Axle

Remove the Front Axle Support for Front-Wheel Drive Axle

Remove Front Axle Support at Front Axle

Installing the Front Axle Support

Install Front Axle Support, Additional Work

Group 10: Machine-Specific Systems – Main Frame

Machine-Specific Systems - Main Frame, Summary of References

Main Frame - Repair Specifications

Main Frame and Attachments

Group 15: Machine-Specific Systems - Front Wheels, Rear Wheels and Fenders

Machine-specific systems - Front wheels, rear wheels, and fender, Summary of references

Front Wheels, Rear Wheels and Fenders - Special Tools

Front Wheels, Rear Wheels and Fenders - Repair Specifications

Front Wheels, Rear Wheels and Fenders - Pivoting Front Fender

Front Wheels, Rear Wheels and Fenders - Removing Front Wheel

Front Wheels, Rear Wheels and Fenders - Reconditioning Front Rim

Front wheels, rear wheels, and fenders - Installing a front wheel

Front Wheels, Rear Wheels and Fenders - Removing the Rear Wheels (with Flanged Axle)

Front Wheels, Rear Wheels and Fenders - Reconditioning the Rear Rim (with Flanged Axle)

Front Wheels, Rear Wheels and Fenders - Installing the Rear Wheel (with Flanged Axle)

Front Wheels, Rear Wheels and Fenders - Removing the Rear Wheel (with Rack-and-Pinion Axle)

Front Wheels, Rear Wheels and Fenders - Reconditioning the Rear Rim (with Rack-and-Pinion Axle)

Front Wheels, Rear Wheels and Fenders - Installing the Rear Wheel (with Rack-and-Pinion Axle)

Front Wheels, Rear Wheels and Fenders - Installing the Reinforced Rear Wheel

Group 20: Machine-Specific Systems – Trailer Hitch and Swinging Drawbar

Machine-Specific Systems - Trailer Hitch and Swinging Drawbar, Summary of References

Repair Specifications

Check the Manually-Operated Hitch for Wear

Check the Manually-Operated Hitch for Wear (Italy and Spain Only)

Check the Remote-Controlled Trailer Hitch for Wear

Trailer Hitch, Checking the Guide Rails

Checking the Tow-Hook for Wear

Checking the Hitch Ball for Wear

Check Drawbar for Wear

Removing and Installing the Center Link Bracket

Removing and Installing the Guide Rails

Reconditioning the Automatic Trailer Hitch

Remote Control for Automatic Trailer Hitch

Reconditioning the Height-Adjustable Trailer Hitch (Italy and Spain Only)

Drawbar

Swinging Drawbar with Pick-Up Hitch

Tightening Torques on High-Clearance Drawbar

Adjusting the High-Clearance Drawbar

Adjusting the Holding Tab

Attaching Safety Decals on the Swinging Drawbar

Group 25: Machine-Specific Systems - Hydraul. Wagon Hitch

Machine-Specific Systems - Hydraulic Pick-Up Hitch, Summary of References

Repair Specifications

Hydraulic Pick-Up Hitch — General Safety and Repair Information

Check Tow Hook on Pick-Up Hitch for Wear

Removing and Installing the Pick-Up Hitch

Pick-Up Hitch - Exploded View

Pick-Up Hitch - Control Lever and Lift Links

Pick-Up Hitch - Hydraulic Parts

Electro-Hydraulic Pick-Up Hitch (E-PUH) - Electro-Hydraulic Parts

Reconditioning the Retainer Spring

Pick-Up Hitch - Recondition the Latch Housing

Recondition the Hydraulic Cylinder

Section 80B: Suspension Systems

Group 10: Suspension Systems - Suspended Front-Wheel Drive Axle

Suspension Systems - Suspended Front-Wheel Drive Axle, Summary of References

Suspension Systems - Special Tools, Summary of References

Repair Specifications

Relieving Hydraulic System Pressure

Removing/Installing the Oscillation Limiter

Remove the Panhard Link

Install the Panhard Link

Removing and Installing Linkage

Removing Position Sensor of Suspended Front-Wheel Drive Axle

Reconditioning Position Sensor of Suspended Front-Wheel Drive Axle

Installing Position Sensor of Suspended Front-Wheel Drive Axle

Remove Hydraulic Cylinder

Recondition the Hydraulic Cylinder

Install Hydraulic Cylinders

Remove the Control Block

Recondition the Valves in the Control Block

Install the Control Block

Removing and Installing the Accumulator

Reconditioning the Accumulator

Remove and Recondition the Bearing Support

Install the Bearing Support

Group 15: Suspension Systems - Cab Suspension

Suspension Systems - Cab Suspension, Summary of References

Important Instructions

Repair Specifications

Relieving Hydraulic System Pressure

Removing and Installing Linkage

Removing and Installing the Cab Position Sensor

Removing and Installing the Accumulator

Reconditioning the Accumulator

Removing and Installing Hydraulic Cylinders

Removing and Installing the Proportional Solenoid Valve

Removing and Installing the Panhard Link

Bleeding Air from the Cab Suspension Hydraulic Cylinders

Section 90: Operator's Cab

Group 00: Operator's Cab - Installation and Removal of Components

Operator's Cab - Removal and Installation of Components, Summary of References

Tilt or Remove the Operator's Cab - Special Tools

Tilting or Removing the Operator's Cab - Screw Torques

Tilt the Operator's Cab Upward and Downward - Special Tools

Tilt the Operator's Cab Upward

Tilting the Operator's Cab Downward

Removing the Operator’s Cab

Installing the Operator's Cab

Group 10: Operator's Cab - Operation and Control Devices

Operator's Cab - Operation and Control Devices, Summary of References

Operation and Control Devices - Replacing an Ignition Key with Chip (Immobilizer)

Operation and Control Devices - Dome Light, Removal and Installation

Operation and Control Devices - Console Lighting, Removal and Installation

Group 15: Operator's Cab - Air-Conditioning System

Operator's Cab - Air-Conditioning System, Summary of References

Air-Conditioning System - Special Tools, Summary of References

Air-Conditioning System - Repair Specifications

Air Conditioning System - Observing AC Hose Torques

Air Conditioning System - Safety at Work

Air Conditioning System - Storage of Refrigerant Containers

Air-Conditioning - Important

Air Conditioning System - Service Work

Air Conditioning System - Preventive Maintenance

Air Conditioning System - Test with Air-Conditioning Service Unit

Air-Conditioning System - Air-Conditioning Service Unit, Filling with Refrigerant Oil

Air conditioning system - Instructions for starting up the DENSO air conditioning compressor

Air-Conditioning System - Leak Test

Air-Conditioning System - Removing the Compressor

Air conditioning system - Checking level in the compressor

Air-Conditioning System - Disassembling the Magnetic Clutch

Air Conditioning System - Checking the Clutch Hub Clearance

Air conditioning system - Installing the compressor

Air Conditioning System - Removing and Installing Condenser

Air Conditioning System - Removing/Installing Receiver-Drier

Air Conditioning System - Access to Components of the Air Conditioning

Air Conditioning System - Remove and Install the Evaporator with Expansion Valve

Air-Conditioning System - Replace Expansion Valve

Air Conditioning System - Installing the Condensation Drain Hoses

Air Conditioning System - Remove and Install the Fan Motor

Air Conditioning System - Removing and Installing the Cab Air Filters

Air Conditioning System - Remove and Install the Interior Filter

Air Conditioning System - Remove and Install the Evaporator Temperature Sensor (B129)

Air Conditioning System - Remove and Install the Refrigerant Pressure Sensor (B130)

Air Conditioning System - Remove and Install the Heater Valve (B131)

Air Conditioning System - Remove and Install the Actuator for Air Distribution (B132)

Air Conditioning System - Remove and Install the ETC Control Unit

Group 20: Operator's Cab - ClimaTrak™

Operators's Cab - ClimaTrak™, Summary of References

ClimaTrak™ - Repair Specifications

ClimaTrak™ - Remove and Install the ATC Control Unit

ClimaTrak™ - Removing and Installing the Ambient Temperature Sensor (Front) (B125)

ClimaTrak™ - Removing and Installing the Ambient Temperature Sensor (Rear) (B126)

ClimaTrak™ - Removing and Installing the Sensor for Inside Air Temperature (B127)

ClimaTrak™ - Removing and Installing the Sensor for Outlet Air Temperature (B128)

ClimaTrak™ - Remove and Install the Refrigerant Pressure Sensor (B130)

ClimaTrak™ - Removing and Installing the Defog Sensor (B143)

ClimaTrak™ - Sensor for Pressure Inside Cab (B213)

ClimaTrak™ - Pressurizer Blower Motor for Pressure Inside Cab (M07)

Group 30: Operator's Cab - Seats

Operator's Cab - Seat, Summary of References

Seat Tools — Summary of References

Repair Specifications

Other Material

General Information on Seat Repairs

Air Comfort Seat MSG95GL, Removal and Installation

Air Comfort Seat MSG95GL, Boot Removal and Installation

Air Comfort Seat MSG95GL - Removal and Installation of Compressor

Air Comfort Seat MSG95GL - Air Spring Removal and Installation

Air Comfort Seat MSG95GL - Seat Suspension Removal and Installation

Air Comfort Seat MSG95GL, Vehicle Connection Harness, Removal and Installation

Air Comfort Seat MSG95GL - Seat Suspension Harness, Removal and Installation

Air Comfort Seat MSG95GL - Actuation for Height Adjustment Removal and Installation

Air Comfort Seat MSG95GL, Check and Adjust the Bowden Cables for Height Adjustment

Air Comfort Seat MSG95GL, Removal and Installation of Bowden Cable for Height Adjustment Downward

Air Comfort Seat MSG95GL, Removal and Installation of Bowden Cable for Height Adjustment Upward

Air Comfort Seat MSG95GL, Level Control Removal and Installation

Air Comfort Seat MSG95GL - Adjust Level Control (Micro-Switch, Vent Valve)

Air Comfort Seat MSG95GL - Air Hoses Removal and Installation

Air Comfort Seat MSG95GL - Air Distributor Removal and Installation

Recondition the CommandARM™

Instructional Seat, Seat Belt Removal and Installation

Group 35: Operator's Cab - Operator's Cab

Operator's Cab, Summary of References

Special Tools - Summary of References

Cab Frame, Removal and Installation

Cab mounting, torques

Rear Post Cover, Removal and Installation

Front Post Cover, Removal and Installation

Storage Compartment, Removal and Installation

Sunshade, Removal and Installation

Panorama Door, Removal and Installation

Panoramic Windshield, Removal and Installation

Adjust the Door Lock

Side Panel, Removal and Installation

Outer Roof, Removal and Installation

Panoramic Roof, Removal and Installation

Section 300: Special Tools

Group 05: General Information

Special Tools - General Information

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