Complete Repair Service Technical Manual for John Deere 2WD or MFWD Tractors 6105E, 6120E & 6135E Final Tier IV (October 2015-), with all the shop information to maintain, repair, and service like professional mechanics.

John Deere 6105E, 6120E, 6135E Final Tier IV (from 10.2015) 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.

tm608619 - 6105E, 6120E and 6135E Final Tier IV Tractors Repair Technical Manual (October 2015) Technical Manual.pdf
tm608619 - 6105E, 6120E and 6135E Final Tier IV Tractors Repair Technical Manual (October 2015) Technical Manual.epub

PRODUCT DETAILS:
Total Pages: 915 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

TABLE OF CONTENTS
Foreword
   General Information
      Safety
      General Information
      Fuel and Lubricants
      Serial Number Locations
   Engine Repair
      Engine
      Cooling System
   Fuel, Air Intake, and Exhaust Systems
      Fuel System
      Air Intake System
      Exhaust System
   Electrical System
      Charging Circuit
      Starting Circuit
      Electrical System Components
      Wiring Harnesses
   Drive Systems and Transmission
      Towing
      Component Removal
      PTO
      Clutch
   Steering and Brakes
      Steering Repair
      Front Axle-2WD
      Front Axle-MFWD
      Brake Repair
   Hydraulics
      Hydraulic Pump
      Hydraulic Oil Cooler
      Hitch Valve
      Hydraulic Rear Selective Control Valve
      Hydraulic Mid-Mount Selective Control Valve
   Miscellaneous
      Hood and Fenders
      Hitch and Drawbar
      Front Support
   Open Operator Station Repair
      Seat and Support
      ROPS
      Operator Platform
      Cowl Repair
   Cab-Operator Station Repair
      Removal and Installation of Components
      Air Conditioning System
      Heating System
      Seat
   Special Tools
      Dealer Fabricated Tools
      Service Tools

tm608619 - 6105E, 6120E and 6135E Final Tier IV Tractors Repair Technical Manual (October 2015)

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

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

Dispose of Waste Properly

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

Group 10: General Information

Sealants and Adhesives Cross-Reference Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal And O-Ring Stud End Fitting Torque Chart—Standard Pressures

Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures

SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Identify Zinc-Flake Coated Fasteners

Use Torque Wrench Adapter

Glossary of Terms

Group 15: Fuel and Lubricants

Filling Fuel Tank

Filling Diesel Exhaust Fluid (DEF) Tank

Alternative and Synthetic Lubricants

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

John Deere COOL-GARD™ II Coolant Extender

Water Quality for Mixing with Coolant Concentrate

Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines

Disposal of Diesel Exhaust Fluid (DEF)

Refilling Diesel Exhaust Fluid (DEF) Tank

Storing Diesel Exhaust Fluid (DEF)

Testing Diesel Exhaust Fluid (DEF)

Testing Coolant Freeze Point

Extended Diesel Engine Oil Service Intervals

Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines

John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Oil Filters

Fuel Filters

Diesel Fuel

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

BioDiesel Fuel

Minimizing the Effect of Cold Weather on Diesel Engines

Supplemental Diesel Fuel Additives

Grease

Mixing of Lubricants

Lubricant Storage

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

Oilscan™ and CoolScan™

Group 20: Serial Number Locations

Serial Numbers

Product Identification Number

MFWD Axle Serial Number (If Equipped)

Engine Serial Number

Fuel Injection Pump Serial Number

Transaxle Serial Number

Cab Serial Number

Selective Control Valve (SCV) Serial Number

Section 20: Engine Repair

Group 05: Engine

Essential or Recommended Tools

Other Material

Specifications

Remove Engine

Install Engine

Remove and Install Rocker Arm Cover

Repair Engine—Use CTM

Group 10: Cooling System

Essential or Recommended Tools

Specifications

Test Radiator and Deaeration Tank

Test Radiator Cap

Drain Coolant

Remove and Install Radiator

Remove and Install Cooling Package

Remove and Install Deaeration Tank

Replace Belt Tensioner

Remove and Install Viscous Clutch

Cooling System Repair—Use CTM

Section 30: Fuel, Air Intake, and Exhaust Systems

Group 05: Fuel System

Specifications

Remove and Install Fuel Tank

Remove and Install DEF Tank

Replace Fuel Level Sender

Remove and Install Fuel Supply Pump

Remove, Inspect and Install Fuel Cooler

Replace Fuel Strainer and In-Line Check Valve

Group 10: Air Intake System

Specifications

Remove, Inspect and Install Air Cleaner Elements

Remove and Install Air Cleaner

Remove, Inspect and Install Charge Air Cooler (CAC)

Air Intake Pipe Connections

Group 15: Exhaust System

Other Material

Specifications

Repair Engine Exhaust System Components—Use CTM

Remove and Install DEF Dosing Injector

Remove and Install After treatment Device

Remove and Install Decomposition Tube

Remove and Install Exhaust Pipe and Selective Catalyst Reduction (SCR) Assembly

Section 40: Electrical System

Group 05: Charging Circuit

Specifications

Repair Alternator—Use CTM

Remove and Install Alternator

Group 10: Starting Circuit

Specifications

Repair Starter—Use CTM

Remove and Install Starter Motor

Group 15: Electrical System Components

General Repair Procedures

Repair Engine Electrical System Components—Use CTM

Remove and Install Battery

Remove and Install Instrument Panel

Replace Key Switch

Remove and Replace Light Switch

Replace Turn Signal Switch

Remove and Replace EH Directional Reverser Lever

Remove and Install Acceleration Potentiometer (Shuttle Control)

Replace Horn Switch

Replace Starter Relay

Replace Speakers

Replace Antenna

Replace Wiper Control Switch

Remove And Install Wiper Motor

Replace Blower Control Switch

Replace Air Conditioning Temperature Control Switch

Replace Blower Motor Resistor

Replace A/C High/Low Pressure Switch

Replace Dome Light

Replace Door Switch

Replace Electro-Hydraulic Control (EHC) Unit—OOS

Replace Electro-Hydraulic Control (EHC) Unit—Cab

Replace Engine Control Unit (ECU)

Group 20: Wiring Harnesses

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Repair AMP™ Connector

Repair AMPSEAL 16™ Connectors

CAN Controlled SCV Connectors

Remove Connector Body from Blade Terminals

CINCH™ Control Unit Connectors

Exploded View—CINCH™ FlexBox Connectors

CINCH™ FlexBox Connectors

Repair CPC™ Blade Type Connectors

Repair CPC™, Large Mate-N-Loc™, and Metrimate™ Pin Type Connectors

Repair DEUTSCH™ Connectors

Repair ITT Connector

Repair Small Mate-N-Loc™ Socket Connector

Repair Small Mate-N-Loc™ Pin Connector

Repair (Pull Type) Metri-Pack™ Connectors

Repair (Push Type) Metri-Pack™ Connectors

Repair Molex™ Control Unit Connectors

Repair Molex™ Connector

Repair SUMITOMO™ Connectors

Repair Tyco™ Fuel Injector Connector

Repair WEATHER PACK™ Connector

Repair YAZAKI™ Connectors

Replace W010 Positive Battery Cable

Replace W011 Negative Battery Cable

Replace W012 Engine Power Cable

Replace W013 Cab Power Cable

Replace W014 OOS Power Cable

Replace W021 Operator Station Ground Cable

Replace W100 Hood Harness

Replace W300 Chassis Harness (PR, OOS)

Replace W320 Engine Harness

Replace W502 Cab Harness

Replace W572 Transmission Harness

Replace W600 DEF Harness

Replace W700 Mid-Mount SCV Harness (Cab)

Replace W701 Mid-Mount SCV Harness (OOS)

Replace W902 Front Console Harness

Replace W920 Roof Harness

Section 50: Drive Systems and Transmission

Group 00: Towing

Towing Tractor (12 Speed Transmission)

Group 05: Component Removal

Essential or Recommended Tools

Other Material

Specifications

Transaxle Separation and Repair

Transmission Component Identification

Transmission Drain Plug Locations

Remove and Install Rear PTO Drive Shaft Assembly

Remove and Install Final Drive Assembly

Remove, Inspect and Install MFWD Drive Shaft

EH-MFWD Component Identification

Remove and Install MFWD Drop Gearbox (If Equipped)

Remove and Install EH-MFWD Drop Gearbox (If Equipped)

Split Tractor

Group 10: PTO

PTO Repair—Use CTM

PTO Component Identification

PTO Clutch Component Identification

Group 15: Clutch

Essential or Recommended Tools

Other Material

Specifications

Remove, Inspect, and Repair Clutch Pedal and Linkage—PR Transmission

Remove and Install Clutch Pedal Position Sensor

Adjust Interlock Cable

Section 60: Steering and Brakes

Group 05: Steering Repair

Other Material

Specifications

Remove and Install Steering Wheel

Remove and Install Tilt/Telescoping Steering Column

Remove and Install Steering Valve (Open Operator Station)

Remove and Install Steering Valve (Cab Tractors)

Disassemble and Inspect Steering Valve

Assemble Steering Valve

Start-Up Procedure After Hydraulic System Repairs

Group 10: Front Axle—2WD

Essential or Recommended Tools

Other Material

Specifications

Remove Front Axle—2WD

Install Front Axle—2WD

Disassemble Front Axle—2WD

Assemble Front Axle—2WD

Adjust Knuckle and Spindle Assembly Axial Play—2WD

Assemble Wheel Hub—2WD

Adjust Wheel Bearings—2WD

Remove and Install Axle Pivot Pins/Bushings—2WD

Install Tie Rod—2WD

Check And Adjust Toe-In—2WD

Remove and Install Steering Cylinder—2WD

Disassemble, Inspect and Assemble Steering Cylinder—2WD

Group 15: Front Axle—MFWD

Essential or Recommended Tools

Specifications

Remove, Inspect and Install Tie Rod Assembly—MFWD

Check And Adjust Toe-In—MFWD

Remove and Install Steering Cylinder—MFWD

Disassemble, Inspect and Assemble Steering Cylinder—MFWD

Remove Front Axle—MFWD

Install Front Axle—MFWD

Group 20: Brake Repair

Specifications

Remove and Replace Brake Pedals and Linkage

Adjust Brake Linkage and Pedal Travel

Section 70: Hydraulics

Group 05: Hydraulic Pump

Essential or Recommended Tools

Specifications

Remove and Install Hydraulic Pumps

Disassemble, Inspect and Assemble Hydraulic Pumps

Group 10: Hydraulic Oil Cooler

Remove, Inspect and Install Hydraulic Oil Cooler

Group 15: Hitch Valve

Other Material

Specifications

Disassemble and Assemble Control Linkages and Levers—(OOS)

Disassemble and Assemble Control Cables and Levers—(Cab)

Inspect and Repair Hitch Control Box

Remove and Install Hitch Valve

Replace Main Relief Valve

Replace Shock Relief Valve

Remove, Inspect and Install Rate-of-Drop Valve

Remove, Inspect and Install Load Sense Relief Valve

Inspect and Repair Draft Sensing Assembly

Install Draft Link Shaft

Remove, Inspect and Install Lift Arms

Remove, Inspect and Install Lift Cylinders

Draft Control and Position Control Linkage Adjustment—OOS

Draft Control and Position Control Cable Adjustment—Cab

3-Point Hitch Position Feedback Linkage Adjustment

Draft Sensing Feedback Cable Adjustment

Group 20: Hydraulic Rear Selective Control Valve

Other Material

Specifications

Inspect and Repair SCV Levers and Linkage (Cab)

Remove and Install Rear Selective Control Valve (SCV)

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

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

Rear SCV Control Cable Adjustment

Group 25: Hydraulic Mid-Mount Selective Control Valve

Other Material

Specifications

Inspect and Repair Multi-Function Lever and Linkage

Remove and Install Mid-Mount Selective Control Valve (SCV)

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

Disassemble, Inspect, and Assemble Triple Mid-Mount Selective Control Valve (SCV)

Mid-Mount SCV Control Cable Adjustment

Section 80: Miscellaneous

Group 05: Hood and Fenders

Remove and Install Fenders—Cab Tractors

Remove and Install Fenders—OOS Tractors

Remove and Install Hood

Group 10: Hitch and Drawbar

Specifications

Remove and Install Drawbar and Support

Remove 3-Point Hitch Linkage

Inspect and Repair Stabilizer Chains (If Equipped)

Inspect and Repair Stabilizer Bars (If Equipped)

Inspect and Repair Lower Draft Links

Inspect and Repair Standard Lift Link

Inspect and Repair Adjustable Lift Link

Inspect and Repair Center Link

Remove and Install Trailer Hitch (If Equipped)

Checking the Manually Operated Hitch (EEC Type) for Wear (If Equipped)

Checking the Manually Operated Hitch (CUNA Type) for Wear (If Equipped)

Group 15: Front Support

Essential or Recommended Tools

Specifications

Remove, Inspect, and Install Front Support

Section 90: Open Operator Station Repair

Group 05: Seat and Support

Specifications

Remove and Install Seat and Support

Group 10: ROPS

Specifications

Check ROPS

Remove and Install ROPS

Group 15: Operator Platform

Other Material

Specifications

Remove Operator Station

Install Operator Station

Group 20: Cowl Repair

Remove and Install Cowl

Section 95: Cab—Operator Station Repair

Group 05: Removal and Installation of Components

Essential or Recommended Tools

Specifications

Remove, Inspect, and Install Cab Interior Recirculating Air Filters

Remove, Inspect, and Install Exterior Cab Intake Air Filters

Remove and Install Headliner

Remove and Install Right-Side Control Console

Remove and Install Left-Side Control Console

Remove and Install Left-Hand Upholstery

Remove and Install Right-Hand Upholstery

Remove and Install Cowl

Remove and Install Windshield

Remove and Install Rear Window

Remove and Install Front Lower Windows

Remove and Install Rear Lower Window

Remove and Install Side Windows

Remove and Install Cab Doors

Remove and Install Cab Roof

Remove and Install Safety Exit Door (If Equipped)

Installing Door Lock

Remove Operator Cab

Install Operator Cab

Group 10: Air Conditioning System

Essential or Recommended Tools

Other Material

Specifications

Recover/Recycle Air Conditioning Refrigerant

Replace Air Conditioning Receiver-Dryer

Remove, Inspect, and Install Air Conditioning Condenser

Remove, Inspect, and Install Air Conditioning Compressor

Test Volumetric Efficiency of Compressor

Test Compressor Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Disassemble, Inspect, and Assemble Compressor

Check Compressor Clutch Hub Clearance

Inspect Compressor Manifold

Remove and Install the Evaporator and Expansion Valve

Arrangement of Condensation Water Drain Hoses

Remove and Install A/C Thermostat Switch

Adjust Thermostat Switch Bowden Cable

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

System Information

Flush Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Group 15: Heating System

Remove and Install Heater Core

Remove and Install Fan Motors

Remove and Install Fan Motor Resistors

Remove and Install Heater Valve

Adjust Heater Valve Bowden Cable

Group 20: Seat

Remove and Install Seat and Support

Remove and Install Instructional Seat

Section 99: Special Tools

Group 05: Dealer Fabricated Tools

DFRW20—Compressor Holding Fixture

DFRW242—Modification to KJD10539 Support Stand Adapter

DFRW243—Short Adapter

Group 10: Service Tools

Essential or Recommended Tools

John Deere Tractors 6105E, 6120E, 6135E Final Tier IV Repair Service Manual (TM608619)