John Deere Tractors 6105J, 6140J, 6140JH, 6155J, 6155JH, 6105JH Repair Service Manual (TM609319)

tm609319 - 6105J, 6140J, 6140JH, 6155J and 6155JH Tractors, Repair Technical Manual (November 2015) Technical Manual.pdf

Complete Repair Service Technical Manual for John Deere 2WD or MFWD Tractors 6105J, 6140J, 6140JH, 6155J & 6155JH, with all the technical information to maintain, repair, rebuild like professional mechanics.

John Deere 6105J, 6140J, 6140JH, 6155J, 6155JH Tractors 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: 1,881 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   Safety
      Safety Precautions
   General Information
      Specifications
      Tune-Up
      Pre-Delivery Inspections
   Engine
      Remove And Install Engine
   Fuel, Intake, Cooling and Exhaust Systems
      Speed Control Linkage
      Fuel System
      Air Intake System
      Cooling System
      Exhaust System
   Electrical System
      Connectors
      Wiring Harnesses
      Charging circuit
      Starter Motor Electrical Circuit
      Fuses, Relays and Switches
      Control Systems
      Electrical Components
   SyncroPlus Transmission
      Removing and Installing Transmission Components
      Transmission Controls
      Perma Clutch II
      Gear Case
      Creeper Transmission
      Range Transmission
   PowrQuad Transmission
      Component Removal and Installation
      Transmission Controls
      PowrQuad Module
      Range Box
   Drive Systems
      Component Removal and Installation
      Drive Shafts and Torsional Dampener
      MFWD Clutch
      Differential
      Differential (6105J OOS)
      Hydraulic Pump Drive
      Final Drive
      Final Drive (6105J OOS)
      Final Drives on Hi-Crop Tractors
      PTO
      PTO (6105J OOS)
   Steering and Brakes
      Hydrostatic Steering
      Steering Cylinders
      Brake Valve
      Rear Brakes
   Hydraulic System
      Controls
      Hydraulic Pump And Charge Pump
      Valves
      Hydraulic Rockshaft
      Selective Control Valves And Couplers
   Miscellaneous
      Component Removal and Installation
      Main Frame
      Front Axle
      Hi-Crop Front Axle
      Front and Rear Wheels
      Swinging Drawbar
   Operator`s Cab
      Removing and Installing Components
      Air Conditioning System
      Heating System
      Operator`s Cab
   Deluxe Seat
      Seat and Support
      Roll-Over Protective Structure (ROPS)
      Rockshaft Electronic Control Components
   Special Tools (Dealer Fabricated)
      Special Tools (Dealer Fabricated)
      Special Tools (Available at the Dealership)

tm609319 - 6105J, 6140J, 6140JH, 6155J and 6155JH Tractors, Repair Technical Manual (November 2015)

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Precautions

Recognize Safety Information

Understand Signal Words

Replace Safety Signs

Follow Safety Instructions

Work In Ventilated Area

Practice Safe Maintenance

Avoid Backover Accidents

Prevent Machine Runaway

Avoid Contact with Agricultural Chemicals

Clean Vehicle of Hazardous Pesticides

Use a Safety Chain

Work in Clean Area

Decommissioning: Proper Recycling and Disposal of Fluids and Components

Avoid Harmful Asbestos Dust

Avoid Hot Exhaust

Clean Exhaust Filter Safely

Handle Fuel Safely—Avoid Fires

Prepare for Emergencies

Handle Fluids Safely—Avoid Fires

Avoid High-Pressure Fluids

Install All Guards

Use Proper Lifting Equipment

Illuminate Work Area Safely

Live With Safety

Service Machines Safely

Support Machine Properly

Remove Paint Before Welding or Heating

Park Machine Safely

Stay Clear of Rotating Drivelines

Use Proper Tools

Service Tires Safely

Keep ROPS Installed Properly

Construct Dealer-Made Tools Safely

Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

Handling Batteries Safely

Service Accumulator Systems Safely

Handle Agricultural Chemicals Safely

Service Cooling System Safely

Use Steps and Handholds Correctly

Deliver Safely

Transport Tractor Safely

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Service Front-Wheel Drive Tractor Safely

Do Not Open High-Pressure Fuel System

Section 10: General Information

Group 05: Specifications

Engine

Transmission

Hydraulic System

Overall Dimensions

Standard Tires

Loads and Weights

Electrical System

Capacities

Hydraulic Forward/Reverse

Power Take-Off

Differential Lock

Final Drive

Front Wheel Drive

Hydraulic Brakes

Park Brake

Hydraulic System with Axial Piston Pump

Hydraulic System with Gear Pump

Hydraulic Rockshaft

Handling and Storing Diesel Fuel

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Transmission, Steering, Brake, Hydraulic, and Gear Case Oil

Front-Wheel Drive Axle Oil

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

MFWD Axle Housing Oil — Hi-Crop Rear Axle

Diesel Engine Coolant

Supplemental Coolant Additives

Testing Coolant Freeze Point

Grease

Oil Filters

Mixing of Lubricants

Lubricant Storage

Operating in Warm Temperature Climates

Alternative and Synthetic Lubricants

Oilscan™ and CoolScan™

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Hydraulic System Fitting Torque Values (in.)

Hydraulic System Metric Fitting Torque Values

Product Identification Number

Engine Serial Number

Transmission Serial Number

MFWD Axle Serial Number

Cab Serial Number

Group 10: Tune-Up

Specifications

Using High-Pressure Washers

Preliminary Engine Test

Tractor Tune-Up

Removing and Cleaning the Primary Air Cleaner Element

Checking the Air Cleaner Safety Element

Installing the Primary Air Cleaner Element

Air Intake System Joint Leak Check

Checking Air Intake Hoses

Checking the Crankcase Vent Hose for Clogging

Keep Radiator Screen Clean

Cleaning Radiator

Expansion Tank Cap Check

Radiator Leak Check

Checking the Engine's Thermostat

Supply Pump Operation Check

Checking the Fuel Filter

Bleeding the Fuel System

Cleaning Water Trap

Transmission Oil - Adjusting the Oil Level Mark at the Sight-Glass

Run Engine until it is Warm and Check Engine Speeds

Cleaning the Battery, Cables and Battery Box with a Clean Cloth

Checking Neutral Start Circuit

Checking Operation of Starting Motor

Checking the Lighting Circuit

Engine Final Check

Tractor Operation Check

Fuel Injection Pump Adjustment Check

Check Speed Control Linkage Adjustment

Group 15: Pre-Delivery Inspections

Predelivery Inspection

Section 20: Engine

Group 00: Remove And Install Engine

Essential or Recommended Tools

Specifications

Engine Removal

Installing the Engine

Section 30: Fuel, Intake, Cooling and Exhaust Systems

Group 05: Speed Control Linkage

Adjust Speed Control Linkage

Hand Throttle Lever — Exploded View

Foot Throttle, Mechanical Speed Control (OOS)

Accelerator Pedal, with Mechanical Speed Control (Cab)

Accelerator Pedal Adjustment

Group 10: Fuel System

General Information

Removing the Fuel Tank

Installing the Fuel Tank

Replacing the fuel gauge sender

Replace Electrical Fuel Transfer Pump

Replace Fuel Filter

Replace Water Separator

Bleed Fuel System

Install Check Valve in Fuel System

Group 15: Air Intake System

General Information

Air Cleaner - Exploded View

Replace Air Filter Restriction Sensor (B02)

Group 20: Cooling System

General Information

Specifications

Remove Radiator

Replace Fan

Remove and Install Expansion Tank

Remove And Install Thermostat

Install Radiator

Filling the Cooling System with Coolant

Relieve the Tension on the Drive Belt

Replace Drive Belt

Replace Drive Belt Tensioner

Repair Fan Bracket

Group 30: Exhaust System

General Information

Specifications

Exhaust System

Section 40: Electrical System

Group 05: Connectors

Essential or Recommended Tools

General

Using high-pressure washers

Disconnecting electrical circuits

Reconditioning Wire Ends

Installing a Terminal

WEATHER PACK Connectors

METRI PACK connector with rear terminal lock

METRI PACK connector with Front Terminal Lock

METRIC PACK Connectors

CAN BUS Terminating Resistor Connector

Electronic Control Unit Connectors

Connectors

CRIMP SNAP IN Connectors

KOSTAL Connectors

DEUTSCH Connectors

Individual terminals

Fuse and Relay Box on Tractors with Cab and Open Operator Station

Group 10: Wiring Harnesses

Disconnecting Electrical Circuits

Location of Ground Points

Remove and Install Wiring Harness W01 — Power Supply (OOS)

Removing and Installing Wiring Harness W01 — Power Supply (Cab)

Removing and Installing Wiring Harness W02 — Engine Wiring Harness (OOS Tractors)

Removing and Installing Wiring Harness W02 — Engine Wiring Harness (6105J OOS)

Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)

Remove and Install Wiring Harness W04 — Headlights

Removing and Installing Wiring Harness W04 — Headlights (6105J OOS)

Remove and Install Wiring Harness W10 — Shift Console

Remove and Install Wiring Harness W11 — Gear Shift and Accelerator Lever

Remove and Install Wiring Harness W13 — Clutch Sensor

Removing and Installing Wiring Harness W19 — Cab Roof

Removing and Installing Wiring Harness W26 — Fan and Air Conditioning

Remove and Install Wiring Harness W28 — Front End of Transmission (OOS)

Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors)

Remove and Install Wiring Harness W30 — Rear End of Transmission (OOS)

Removing and Installing Harness W30 — Rear End of Transmission (Cab)

Remove and Install Wiring Harness W31 — 7-Pin Electrical Accessory Receptacle Connector (if installed)

Remove and Install Wiring Harness W32 - Stepper Motors (if installed)

Windshield Wiper Harness - Rear

Group 15: Charging circuit

Special Tools

Specifications

Repairing the Alternator

Disconnecting Electrical Circuits

Relieve Drive Belt Tension

Remove/Install the Alternator

Pulley Removal and Installation

Group 20: Starter Motor Electrical Circuit

Special or Essential Tools

Specifications

Repairing the Starter Motor

Disconnecting Electrical Circuits

Remove and Install Starter Motor

Group 25: Fuses, Relays and Switches

Special or Essential Tools

Specifications

Disconnecting Electrical Circuits

Fuse and Relay Box - Cab Tractors

Fuse and Relay Box - Tractors with Open Operator Station

Replacing Main Fuses

Replace Main Fuses

Replace Thermo Starting Aid Fuses

Replace Thermo Starting Aid Fuses

Replace Starter Motor Relay

Replace Ignition Switch

Replace Brake Switch

Replace Light Switch

Replace Hazard Light Switch

Replace Turn Signal Switch

Replacing Windshield Wiper and Windshield Washer Switch

Replace MFWD Switch

Replacing Fan Switch

Replace PTO Switch

Replacing Differential Lock Switch

Rockshaft Control

Group 30: Control Systems

Disconnecting Electrical Circuits

Replace Air Filter Restriction Sensor (B02)

Check Engine Speed Sensor (B01)

Replace Engine Oil Pressure Sensor (B04)

Replace Coolant Temperature Sensor (B08)

Replace Wheel Speed Sensor (B09)

Group 40: Electrical Components

Essential or Recommended Tools

Specifications

Disconnecting electrical circuits

Replacing the 7-Terminal Power Outlet Socket

Replace 3-Pin Service Connector (OOS)

Replacing Service Socket (Cab)

Removing Windshield Wiper Motor

Adjusting Front Headlights

Adjusting Cab Frame Lights

Safety Instructions for Replacing a Halogen Bulb

Section 50: SyncroPlus Transmission

Group 00: Removing and Installing Transmission Components

Special Tools

Dealer-Fabricated Special Tools

Specifications

Removing Clutch Housing

Installing Clutch Housing

Removing Gear Transmission Housing

Installing Gear Case

Group 05: Transmission Controls

Specifications

Reconditioning Gear Shift Linkage

Reconditioning Range Shift Linkage

Inspecting and Adjusting Gear Shift and Range Shift Levers

Adjusting Clutch Pedal

Group 10: Perma Clutch II

Special or Essential Tools

Specifications

Removing Clutch

Reconditioning Clutch

Installing Clutch

Removing Transmission Oil Pump

Reconditioning Transmission Oil Pump

Installing Transmission Oil Pump

Valves and other Hydraulic Components

Reconditioning Engagement Override Valve

Reconditioning Clutch Cooling Valve

Reconditioning Cooling Pilot Valve

Reconditioning Filter Relief Valve

Reconditioning Pressure-Regulating Valve

Reconditioning Lube Relief Valve

Reconditioning Cooler Relief Valve

Reconditioning Clutch Pedal Valve

Replacing Temperature and Pressure Sensors

Group 15: Gear Case

Special or Essential Tools

Specifications

Gear Transmission—Cross-Section

Removing Gear Transmission

Reconditioning Gear Transmission

Preparation for Installing the Gear Transmission

Reconditioning Shift Cover

Adjusting Shift Mechanism

Adjusting Neutral Start Switch

Group 20: Creeper Transmission

Specifications

Removing Creeper Transmission

Reconditioning Creeper Transmission

Installing Creeper Transmission

Reconditioning Shift Cover

Group 25: Range Transmission

Specifications

Range Transmission—Cross-Section

Removing Range Transmission

Reconditioning Range Transmission

Installing Range Transmission

Reconditioning Shift Cover

Section 55: PowrQuad Transmission

Group 00: Component Removal and Installation

Special or Essential Tools

Dealer Fabricated Special Tools

Specifications

Remove PowrQuad Transmission

Install PowrQuad Transmission

Remove Range Box

Install Range Box

Group 05: Transmission Controls

Specifications

Repair Gear Shift Linkage

Repair Transmission Gear Shift, Forward/Reverse and Park Brake Cable

Repair Range Shift Cable

Repair Range Shift Linkage

Forward/Reverse Lever Adjustment

Forward-Reverse Linkage Adjustment

Inspect and Adjust Gear Shift Linkage

Adjust Clutch Pedal

Group 10: PowrQuad Module

Special or Essential Tools

Service Equipment or Tools

Other Materials

Specifications

Transmission components

Replace Temperature and Pressure Sensors

Remove and Install Oil Filter Housing

Remove And Install Front Valve Housing

Remove And Install Front Valve Housing Valves

Remove and Install Transmission Front Cover

Remove and Install Transmission Front Cover Valves

Remove And Install Shift Valve Housing

Remove And Install Shift Valve Housing Valves

Remove Transmission Oil Pump

Repair Transmission Oil Pump

Install Transmission Oil Pump

Remove Planetary Gear Shift

Repair Planetary Gear Shift

Install Planetary Gear Shift

Remove B1 Brake Housing

Repair B1 Brake

Install B1 Brake Housing

Remove B2-B3 Brake Housing

Repair B2 Brake

Repair B3 Brake

Install B2-B3 Brake Housing

Remove C4 Clutch

Repair C4 Clutch

Install C4 Clutch

Remove Reverse Brake

Repair Reverse Brake

Install Reverse Brake

Remove Forward Clutch with Planetary Reduction (Forward/Reverse)

Repair Forward Clutch with Planetary Reduction (Forward/Reverse)

Install Forward Clutch with Planetary Reduction (Forward/Reverse)

Replace Output Shaft

Group 20: Range Box

Special Tools

Repair Specifications

Remove Range Box

Range Box—Cross-Sectional View

Repair Range Box

Install Range Box

Repair Shift Cover

Replace Speed Sensor

Section 56: Drive Systems

Group 00: Component Removal and Installation

Special or Essential Tools

Special Tools (Dealer-Fabricated)

Specifications

Remove MFWD Clutch

Install MFWD Clutch

Remove Differential Housing

Install Differential Housing

Remove Final Drive

Install Final Drive

Remove PTO

Install PTO

Group 05: Drive Shafts and Torsional Dampener

Specifications

Remove Drive Shaft (MFWD)

Repair Drive Shaft (MFWD)

Install Drive Shaft (MFWD)

Remove Drive Shaft (Engine)

Remove And Install Annular Cooler

Remove Torsional Dampener

Change Torsional Dampener Bearings

Install Torsion Dampener

Install Drive Shaft (Engine)

Group 10: MFWD Clutch

Special or Essential Tools

Other Materials

Specifications

Disassemble MFWD Clutch

MFWD Clutch—Exploded View

Assemble MFWD Clutch

Group 15: Differential

Special Tools

Specifications

Remove Differential

Differential Cross-Sectional View

Disassemble Differential

Remove Differential Piston

Remove Pinion Gear

Remove Housing Cap Screw

Remove Bevel Pinions

Remove Bevel Side Gear

Disassemble

Assemble Differential

Install Pinion Gear

Install Thrust Washers

Install Bevel Side Gears

Install Shaft Retaining Cap Screw

Install Thrust Washer

Install Splined Disks

Install Piston in Differential Cover

Install Differential Cover

Install Tapered Bearings

Install Differential

Install Shim Pack

Adjust Differential Preload

Adjust Backlash

Final Assembly

Group 15A: Differential (6105J OOS)

Specifications

Removing Differential

Disassemble Differential

Differential — Exploded View

Assembling Differential

Installing Differential

Group 20: Hydraulic Pump Drive

Specifications

Repair Hydraulic Pump Drive

Adjust Hydraulic Pump Drive

Group 25: Final Drive

Service Tools

Special Tools

Other Materials

Specifications

Preparation

General Repair Procedures - Final Drive

Remove Planet Pinion Carrier

Disassemble Planet Pinion Carrier

Assemble Planet Pinion Carrier

Remove Axle Housing

Disassemble and Assemble Axle Housing

Disassemble and Assemble Axle Shaft

Install Axle Housing

Install Planet Pinion Carrier And Check Rolling Drag Torque

Group 25A: Final Drive (6105J OOS)

Special or Essential Tools

Specifications

Reconditioning Final Drives

Group 25B: Final Drives on Hi-Crop Tractors

Service Tools

Specifications

General Repair Procedures—Hi-Crop Final Drive

Cross-Sectional View—Hi-Crop Final Drive

Remove Final Drive

Disassemble Final Drive

Assemble Final Drive

Install Final Drive

Group 30: PTO

Special Tools

Seal Installer

Service Tools

Specifications

General Repair Procedures - PTO

Clean Bearings

Repair Instructions

Repair PTO

Remove and Disassemble Countershaft

Assemble and Install Countershaft

Remove And Disassemble Output Shaft

Assemble and Install PTO Output Shaft

Remove PTO Shifter

Install PTO Shifter

Replace PTO Output Shaft Oil Seal

Remove Modulating Valve

Disassemble and Assemble Modulating Valve

Install Modulating Valve

Replace PTO Speed Sensor

Group 30A: PTO (6105J OOS)

Special or Essential Tools

Special Tools Dealer-Fabricated

Other Materials

Specifications

Replacing Output Shaft Seal Ring

Replacing O-Ring on Reversible PTO

Removing PTO Clutch

Reconditioning PTO Clutch

Installing PTO clutch

Reconditioning PTO Brake

Disassembling PTO Transmission

Reconditioning Output Shaft (540/1000 RPM Reversible)

Mounting Output Shaft (540/1000 RPM)

Reconditioning Countershaft (540/1000 RPM)

Installing PTO Shift Mechanism (540/1000 RPM)

Assembling PTO transmission

Adjusting Tapered Roller Bearing of Output Shaft

Adjusting Tapered Roller Bearing of Countershaft

Installing Support and Adjusting Tapered Roller Bearings

Installing PTO Housing

Removing PTO Modulating Valve

Reconditioning PTO Modulating Valve

Installing PTO Modulating Valve

Reconditioning Solenoid

Replacing PTO Speed Sensor

Section 60: Steering and Brakes

Group 05: Hydrostatic Steering

Special or Essential Tools

Specifications

Preparation

Separating Fixed Column and Steering Valve (-XXXXXX)

Remove Tilt Column and Steering Valve (XXXXXX-)

Disassemble Steering Valve

Steering Valve Exploded View

Assemble Steering Valve

Adjust Relief Valves

Repair Fixed Steering Column (-XXXXXX)

Repair Tilt Steering Column (XXXXXX-)

Group 10: Steering Cylinders

General Information

Special or Essential Tools

Specifications

Remove Steering Cylinder

Disassemble Steering Cylinder

Assemble Steering Cylinder

Install Steering Cylinder

Group 15: Brake Valve

Special Tools (Dealer Fabricated)

Specifications

Preparation

Remove Brake Valve

Disassemble Brake Valve

Exploded View

Assemble Brake Valve

Install Brake Valve

Adjust Brake Pedal

Final Assembly

Bleed Brakes

Group 20: Rear Brakes

Special or Essential Tools

Specifications

Remove Rear Brakes

Repair Brakes

Check Brake Disk Wear

Install Seal on Brake Piston

Install Seal in Brake Housing

Install Brakes

Install Brake Disk

Install Thrust Plate

Check Brake Piston Return Travel and Leakage

Final Assembly

Bleed Brakes

Bleed Brakes (Cont.)

Section 70: Hydraulic System

Group 05: Controls

Specifications

Selective Control Valves — Removing and Installing Control Elements

Selective Control Valves — Adjusting Bowden Cable

Removing and Installing Multi-Function Lever

Adjusting Multi-Function Lever

Group 10: Hydraulic Pump And Charge Pump

Other Material

Specifications

Remove and Install the Charge Pump

Charge Pump - Checking the Lube Oil Valve

Hydraulic Oil Reservoir — Restrictor

Hydraulic Pump - Removing and Installing the Pressure-and-Flow Controller

Hydraulic Pump - Reconditioning the Pressure-and-Flow Controller

Remove and Install the Hydraulic Pump

Recondition Hydraulic Pump

Group 15: Valves

Repair the Valves - Summary of Special Tools

Specifications

Hydraulic System — General Instructions on Safety and Repair

Repair the Priority 1 Control Block

Repair the Priority 2 Control Block

Repair the Priority 3 Control Block

Group 20: Hydraulic Rockshaft

Recondition Rockshaft - Summary of Special Tools

Other Material

Specifications

Rockshaft Valve, Removing and Installing the Stepper Motor

Remove Rockshaft Valve

Recondition the Rockshaft Valve

Install Rockshaft Valve

Rockshaft - Remove and Install the Position Sensor and Toothed Segment

Rockshaft - Remove and Install Rockshaft

Rockshaft - Remove Rockshaft Cylinders

Rockshaft — Reconditioning the Rockshaft Cylinders

Rockshaft - Install Rockshaft Cylinders

Hydraulic Rockshaft - Remove and Install Load Sensors and Draft Link Spindle Shafts

Group 25: Selective Control Valves And Couplers

Specifications

Repair Selective Control Valves (SCV) and Couplers — General Instructions for Safety and Repair

Remove Selective Control Valves (SCV)

Repair the Selective Control Valves (M-SCVs 100)

Repair the Selective Control Valves (M-SCVs 300)

Repair the Selective Control Valves (M-SCV 450)

Install Selective Control Valves (SCV)

Section 80: Miscellaneous

Group 00: Component Removal and Installation

Special or Essential Tools

Dealer Fabricated Special Tools

Specifications

Remove Main Frame

Install Main Frame

Remove Front Axle

Install Front Axle

Remove MFWD Axle

Install MFWD Axle

Remove Front Axle Support

Install Front Axle Support

Group 05: Main Frame

Specifications

Repair Main Frame

Group 10: Front Axle

Special or Essential Tools

Specifications

Remove Front Axle

Repair Front Axle

Install Front Axle

Checking and Adjusting Toe-In

Group 10A: Hi-Crop Front Axle

Service Tools

Specifications

Cross-Sectional View—Planetary Carrier and Wheel Hub

Remove, Recondition, And Install Planetary Carrier And Wheel Hub

Assemble And Install Planetary Carrier And Wheel Hub

Cross-Sectional View—Knuckle Spindle Assembly

Disassemble, Inspect, and Assemble Knuckle Spindle Assembly

Install MFWD Axle Into Repair Stand

Cross-Sectional View—Planetary Carrier-Wheel Hub-Knuckle Spindle-U-Joint/Axle Shaft Assembly

Remove And Install Planetary Carrier-Wheel Hub-Knuckle Spindle-U-Joint/Axle Shaft Assembly

Determine Kingpin Shim Pack

Remove Differential Housing

Cross-Sectional View—Differential Housing

Repair Differential Housing

Assemble Differential

Cross-Sectional View—Differential Drive Shaft and Input Quill

Remove And Disassemble Differential Drive Shaft

Determine Differential Drive Shaft Cone Point Shim Pack

Assemble And Install Differential Drive Shaft

Check Ring Gear Backlash And Determine Differential Case Bearing Cup Shim Pack

Adjust Ring Gear Backlash

Backlash Shim Pack Example and Worksheet

Install Differential Case Bearing Cup and Differential Housing

Disassemble And Assemble Axle Housing

Determine And Install Axle Housing Bearing Cup Shim Pack

Bearing Cup Shim Pack Procedure

Preload Shim Pack Example And Worksheet

Install Axle Housing

Cross-Sectional View—Steering Cylinder Housing Assembly

Remove And Disassemble Steering Cylinder

Cross-Sectional View—Steering Cylinder

Assemble And Install Steering Cylinder

Replace MFWD Pivot Bushing

Group 15: Front and Rear Wheels

Special or Essential Tools

Specifications

Remove Front and Rear Wheels

Repair Front and Rear Wheels

Install Front and Rear Wheels

Group 20: Swinging Drawbar

Specifications

Remove and Install Swinging Drawbar

Section 90: Operator's Cab

Group 00: Removing and Installing Components

Special Tools

Repair Specifications

Tilt Operator's Cab Upward

Tilt Operator's Cab Downward

Removing Operator's Cab

Installing Operator's Cab

Group 15: Air Conditioning System

Special Tools

Specifications

Tightening Torque for Refrigerant Hoses

Safety Regulations

Handling Refrigerant

In the Event of an Emergency

Safety Equipment

Storage of Refrigerant Containers

Refrigerant R134a

Important

Other Material

Specifications

General Information

Filling the Cylinder

Cleaning the Air Conditioning System

Evacuating the System

Adding Oil to the Air Conditioning System

Charging Air Conditioning System

Leak Test

Separating Compressor

Checking Compressor Level

Disassembling the Compressor Clutch

Checking Clutch Hub Clearance

Checking the Compressor Manifold

Installing Compressor

Separating and Installing Condenser

Separating and Installing Drier

Replacing Expansion Valve

Separating and Installing Evaporator and Expansion Valve

Installing Condensation Water Drain Hoses

Layout of Condensation Water Drain Hoses

Separating and Installing Thermostat

Separating and Installing High/Low Pressure Switch

Vacuum Pump — General Information

Group 20: Heating System

Fan and Heater, Disassembling

Removing Cab Air Filter

Separating and Installing Fan

Separating and Installing Heater Regulator

Separating Heater/Evaporator Housing

Group 25: Operator's Cab

Removing Cab Frame

Cab Mounting Torques

Removing and Installing Windshield

Removing and Installing Rear Window

Installing Door Lock

Adjusting Window Contact Pressure

Removing and Installing Operator's Cab Door

Removing and Installing Sun-Visor Roller

Section 95: Deluxe Seat

Group 05: Seat and Support

Specifications

Remove and Install Seat and Support

Group 10: Roll-Over Protective Structure (ROPS)

Specifications

Inspect Roll-Over Protective Structure (ROPS)

Remove Roof (Canopy)

Removing and Installing Fixed Roll-Over Protective Structure (ROPS)

Remove and Install Foldable Roll-Over Protective Structure (ROPS)

Group 20: Rockshaft Electronic Control Components

Disconnect Electrical Circuit

Service Information

Replace Control Unit (BCU)

Replace BCU Actuator

Section 99: Special Tools (Dealer Fabricated)

Group 05: Special Tools (Dealer Fabricated)

Suspension Tool

DFLX13 - Holding Device

DFLX5 - Lifting Eye for Operator's Cab

DFLX10 - Holding Tool

Wooden Wedge

DFRW79 – Piston Holding Tool

DFLX22 – Socket Wrench Insert

DFLX24 - Seal Installer

DFLX25 – Driver

DFLX7 - Turning Device

DFLX8 - Thrust Pieces

DFLX6 - Bushing

DFLX27 – Driver

DFLX23 – Socket Wrench Insert

DFRW29—Final Drive Housing Adapter

DFRW30—Drive Axle Jacking Tool

Group 10: Special Tools (Available at the Dealership)

D01019AA - Single-Stage, Manually Operated Pump

D01042AA – Load-Positioning Sling

D01045AA - Bushing, Bearing and Seal Driver Set

D05007ST - Tractor Splitting Stand

FKM10427 - Crimping Pliers

FKM10461 - Wiring Harness Repair Kit

FKM10464 - Single-Acting Hydraulic Ram

FKM10469 - Crimping Pliers

JDE83 – Flywheel Turning Tool

JDG19 – Special Mounting Brackets

JDG23 – Lifting Sling

JDG359 - Electrical Repair Tool Kit

JDG364 - Extraction Tool

JDG708 - AMP Crimping Tool

JDG749—1.30 m (52 in) Torque Extension

JDG750 – Swivel Socket

JDG776 - Extraction Tool

JDG777 - Extraction Tool

JDG817 - Special Wrench

JDG819 - Seal Installer

JDG1208 - Seal Installer

JDG1369 - Terminal Extraction Tool

JT02043 - Support Stand

JT02044 - Support Stand

JT03248 - Fitting

JT05723 – Medium-Duty Rear Tractor Splitting Stand

JT05724 – Medium-Duty Front Tractor Splitting Stand

JT05725 – Universal Support Stand

KJD10168 - Ring Nut Socket

KJD10169B - Special Puller

KJD10172 - Lifting Tool

KJD10173 - Special Tool

KJD10227 - Special Tool

KJD10501 - Disconnecting Tools (Kit)

OTC27489 - Handle

KJD10557 - Cab Tilting Device