John Deere Tractors 6215, 6415, 6615, 6715 Repair Service Manual (TM4649)

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Price: US$ 59.00

Complete Repair Service Technical Manual for John Deere Tractors 6215, 6415, 6615, 6715, with all the shop information to maintain, repair, service like professional mechanics.

John Deere 2WD or MFWD Tractors 6215, 6415, 6615, 6715 official 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: 1,780 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
 

MAIN SECTIONS
  Foreword
   Version Date
   Safety
      Safety Measures
   General Information
      Specifications
      Tune-Up
      Predelivery Inspection
   Engine
      Engine Removal and Installation
   Fuel, Air Intake, Cooling and Exhaust Systems
      Speed Control Linkage
      Fuel System
      Air Intake System
      Cooling System
      Cold-Weather Starting Aids
      Exhaust System
   Electrical System
      Connectors
      Wiring Harnesses
      Charging Circuit
      Starting Motor Circuit
      Fuses, Relays and Switches
      Monitoring Systems
      Electrical Components
   SyncroPlus Transmission
      Removal and Installation of Transmission Components
      Transmission Shift Controls
      Perma Clutch II Module
      Gear Transmission
   Power Reverser
      Removal and Installation of Power Reverser Module
      Transmission Shift Controls
      Power Reverser Module
      Gear Transmission
   PowrQuad Transmission
      Removal and Installation of Components
      Transmission Shift Controls
      PowrQuad Module
      Creeper Transmission
      Range Transmission
   Drive System
      Removal and Installation of Components
      U-Jointed Shafts and Torsion Damper
      Front-Wheel Drive Clutch
      Differential
      Hydraulic Pump Drive
      Final Drives
      Rear PTO
      Front PTO
      Front Implement Drive
   Steering and Brakes
      Hydrostatic Steering
      Steering Cylinders
      Brake Valve
      Rear Brakes
   Hydraulic System
      Controls
      Hydraulic Pump
      Valves
      Rockshaft
      Selective Control Valves and Couplers
      Independent Control Valve
   Misellaneous
      Removal and Installation of Components
      Main Frame
      Front Axle
      Front and Rear Wheels
      Trailer Mounting and Swinging Drawbar
   Operator's Cab
      Removal and Installation of Components
      Controls and Instruments
      Air-Conditioning System
      Heating System
      Seats
      Operator's Cab
   Special Tools
      Special Tools (Dealer-Fabricated)
      Special Tools (available from the dealer)

Table of Contents - Expanded View

Foreword

Version Date

Section 05: Safety

Group 05: Safety Measures

Recognize Safety Information

”Important” Information

”Note” Information

Prevent Machine Runaway

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Wear Protective Clothing

Practice Safe Maintenance

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

Use Proper Tools

Service Tires Safely

Service Front-Wheel Drive Tractor Safely

Avoid Eye Contact With Radar

Keep ROPS Installed Properly

Replace Safety Signs

Dispose of Waste Properly

Live With Safety

Safety Measures on Electronic Control Units

Section 10: General Information

Group 05: Specifications

References, Specifications

Engine

Cooling System

Injection pump (Stanadyne)

Air Intake System

Electrical System

Hydrostatic steering system

Clutch

SyncroPlus transmission

PowrQuad transmission

Power Reverser

Creeper transmission

Rear PTO

Front PTO

Differential

Differential lock

Final drives

Front wheel drive

Hydraulic brakes

Parking lock

Rockshaft

Front hitch

Ground Speeds

Front and Rear Wheels

Dimensions and Weights

Capacities

Handling and Storing Diesel Fuel

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Break-In Oil

Diesel Engine Oil

Transmission and Hydraulic Oil

Front Wheel Drive Axle Oil

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

Torques for inch fittings used in the hydraulic system

Torques for metric fittings used in the hydraulic system

Product Identification and Sub-Assembly Serial Numbers

Engine serial number

Transmission serial number

Front wheel drive axle serial number

Operator's cab serial number

Operator's seat serial number

Sub-assembly serial numbers

Group 10: Tune-Up

Summary of References (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 Filter Element

Checking the Air Intake System Connections for Leaks

Checking the Crankcase Vent Hose for Clogging

Cleaning the Radiator Grille Screen

Keeping the Radiator Screen Clean

Checking the Caps on the Expansion Tank

Checking the Radiator for Leaks

Checking the Engine Thermostat

Checking the Operation of the Fuel Transfer Pump

Checking the Fuel Filter

Checking the Fuel Filter (Denso/Stanadyne Injection Pump; TIER II Engines)

Bleeding the Fuel System

Bleeding the Fuel System (Stanadyne Injection Pump; TIER II Engines)

Bleeding the Fuel System (Denso Injection Pump; TIER II Engines)

Clean the water trap

Run the engine until it is warm, and check engine speeds

Check setting of fuel injection pump

Check setting of speed control linkage

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

Checking the Neutral Start Circuit

Check operation of starting motor

Checking the lighting circuit

Final engine check

Tractor Operation Check

Group 15: Predelivery Inspection

Predelivery Inspection

Section 20: Engine

Group 00: Engine Removal and Installation

Special or Essential Tools

Specifications

Removing the Engine

Installing the Engine

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

Group 05: Speed Control Linkage

Speed Control Linkage (Summary of References)

General Information

Specifications

Adjusting the Hand Throttle Lever and Accelerator Pedal

Adjusting the Speed Control Linkage

Hand Throttle Lever-Exploded View

Accelerator Pedal On Tractors With Low Platform

Accelerator Pedal, with Mechanical Speed Control

Group 10: Fuel System

Fuel System (Summary of References)

General Information

Special Tool (Dealer-Fabricated)

Removing the Fuel Tank

Installing the Fuel Tank

Replacing the Fuel Gauge Sending Unit

Replace the Fuel Transfer Pump

Changing the Fuel Filter

Bleeding the Fuel System

Group 15: Air Intake System

General Information

Air Cleaner-Exploded View

Replacing the Sending Unit for Air Cleaner Restriction (B02)

Group 20: Cooling System

Cooling System (Summary of References)

General Information

Specifications

Removing the Radiator

Removing and Installing the Ring-Shaped Cooler

Change the Fan or the Viscous Fan Drive

Remove and Install the Intercooler (TIER II engines)

Removing and Installing the Expansion Tank

Removing and Installing the Thermostat Valve

Installing the Radiator

Filling the Cooling System with Coolant

Relieving Tension on the Drive Belt

Replacing the Drive Belt

Replacing the Drive Belt Tensioner

Repairing the Fan Console

Group 25: Cold-Weather Starting Aids

Summary of References (Cold-Weather Starting Aids)

Fuel Preheater

Electrical Starting Aid

Coolant Heater

Group 30: Exhaust System

Summary of References (Exhaust System)

General Information

Specifications

Exhaust to Top Right

Exhaust to Bottom Right

Section 40: Electrical System

Group 05: Connectors

Special Tools

General

Using high-pressure washers

Disconnecting electrical circuits

Stripping Wire Ends

Installing Electrical Connectors

METRI PACK Connector with Terminal Lock at the Rear

METRI PACK Connector

Connectors for Electronic Control Units

Connectors

CRIMP SNAP IN connectors

DEUTSCH Connectors

Individual Terminals

Fuse and Relay Boxes

Group 10: Wiring Harnesses

Wiring Harnesses - Summary of References

Wiring Harnesses for Tractors with Open Operator's Station and TIER I Engine - Summary of References

Wiring Harnesses for Tractors with Open Operator's Station and TIER II Engine - Summary of References

Wiring Harnesses for Tractors with Open Operator's Station from Serial No. 399888 - Summary of References

Wiring Harnesses for Cab-Tractors with TIER I Engine - Summary of References

Wiring Harnesses for Cab-Tractors with TIER II Engine - Summary of References

Wiring Harnesses for Cab-Tractors from Serial No. 391068 - Summary of References

Disconnecting electrical circuits

Ground Point Locations

Remove and Install Harness W01 - Power Supply (Open Operator's Station)

Removing and Installing Harness W01 - Power Supply (Cab-Tractors)

Removing and Installing Harness W02 - TIER I Engine (Open Operator's Station)

Removing and Installing Harness W02 - TIER II Engine (ECU Level 12) (Open Operator's Station)

Removing and Installing Harness W02 - TIER I Engine (Cab-Tractors)

Removing and Installing Harness W02 - TIER II Engine (ECU Level 12) (Cab-Tractors)

Removing and Installing Harness W03 - Starting Aid

Removing and Installing Harness W03/2 - Starting Aid (ECU Level 12) from Serial No. 398656

Removing and Installing Harness W04 - Headlights

Removing and Installing Harness W07 - Front PTO

Removing and Installing Harness W08 - Open Operator's Station, with TIER I Engine

Removing and Installing Harness W08 - Open Operator's Station, with TIER II Engine

Removing and Installing Harness W08/2 - Open Operator's Station from Serial No. 399888

Removing and Installing Harness W08 - Cab, with TIER I Engine

Removing and Installing Harness W08 - Cab, with TIER II Engine

Removing and Installing Harness W08/3 - Cab from Serial No. 391068

Removing and Installing Harness W09 - Cowl, with TIER I Engine (Open Operator's Station)

Removing and Installing Harness W09 - Cowl, with TIER II engine (Open operator's station)

Removing and Installing Harness W09 - Cowl, with TIER I Engine (Cab-Tractors)

Removing and Installing Harness W09 - Cowl, with TIER II Engine (Cab-Tractors)

Removing and Installing Harness W14 - 3-Terminal Power Outlet Socket

Removing and Installing Harness W19 - Cab Roof

Removing and Installing Harness W20 - Headlights on cab frame

Removing and Installing Harness W26 - Fan and Air Conditioner

Removing and Installing Harness W27 - Turn Signal Lights

Remove and Install Harness W28 - Front End of Transmission (Open Operator's Station)

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

Removing and Installing Harness W30 - Rear End of Transmission (Open Operator's Station)

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

Removing and Installing Harness W31 - 7-Terminal Power Outlet Socket

Removing and Installing Harness W43 - Backup Alarm

Removing and Installing Harness W44 - Back-up Alarm / Switch for Power Reverser or PowrQuad Transmission

Removing and Installing Harness W45 - Backup Alarm / Switch for SyncroPlus Transmission

Removing and Installing Harness W59 - Light on Cab Frame, Adapter

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: Starting Motor Circuit

Special or Essential Tools

Specifications

Repairing the Starting Motor

Disconnecting Electrical Circuits

Removing and Installing the Starter Motor

Group 25: Fuses, Relays and Switches

Note

Specifications

Fuses, Relays and Switches - Reconditioning (Summary of References)

Remove Trim Panels from Cowl

Disconnecting electrical circuits

Fuse and Relay Box on Tractors with Open Operator's Station

Fuse and Relay Boxes on Cab-Tractors

Replacing the Main Fuses

Replacing Fuses of Electric Starting Aid

Replacing Starting Motor Relay

Replacing Relay of Electric Starting Aid

Replacing Main Switch

Replacing the Brake Switches

Replacing the Light Switch

Replacing Full/Dipped-Beam Switch

Replacing the Worklight Switches

Replacing the Beacon Light Switch

Replacing the Hazard Warning Light Switch

Replacing the Turn Signal Switch

Replacing the Horn Switch

Replacing the Windshield Wiper and Washer Switch

Replacing the front-wheel drive switch

Replacing the Back-Up Alarm Switch

Replacing the Fan Switch

Replacing the Differential Lock Switch

Replacing the PTO Switches

Replacing the Rockshaft Remote Control Switch

Rockshaft control

Group 30: Monitoring Systems

Note

Note

Monitoring Systems - Repair (Summary of References)

Disconnecting electrical circuits

Replacing the Engine Speed Sending Unit (B01)

Replacing the engine oil pressure sending unit (B04)

Replacing the Sending Unit for the Coolant Temperature Gauge (B08)

Replacing the Acoustic Alarm

Group 40: Electrical Components

Note

Special Tools

Specifications

Electrical Components - Reconditioning (Summary of References)

Disconnecting electrical circuits

Replacing the 7-Terminal Power Outlet Socket

Replacing the 3-Terminal Power Outlet Socket

Replacing the Multiple Power-Outlet Socket Strip

Replacing the Service Socket

Removing the Wiper Motor

Adjusting the Headlights

Adjusting the Lights on the Cab Frame

Safety Instructions for Replacing a Halogen Bulb

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

Replacing Xenon (HID) Worklights and Ballast Units

Section 50: SyncroPlus Transmission

Group 00: Removal and Installation of Transmission Components

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Clutch Housing

Installing the Clutch Housing

Removing the Gear Transmission

Installing the Gear Transmission

Group 05: Transmission Shift Controls

SyncroPlus Transmission Shift Units - Reconditioning (Summary of References)

Specifications

Reconditioning the Gear Shift Mechanism

Reconditioning the Range Shift Mechanism

Checking and Adjusting the Shift Units

Adjusting the Clutch Pedal

Group 10: Perma Clutch II Module

SyncroPlus Transmission, Perma Clutch II Module - Reconditioning (Summary of References)

Special or Essential Tools

Specifications

Removing the Clutch

Reconditioning the Clutch

Installing the Clutch

Removing the Transmission Oil Pump

Reconditioning the Transmission Oil Pump

Installing the Transmission Oil Pump

Valves and Other Hydraulic Components

Reconditioning the Engagement Override Valve

Reconditioning the Clutch Cooling Valve

Reconditioning the Cooling Pilot Valve

Reconditioning the Filter Relief Valve

Reconditioning the Pressure-Regulating Valve

Reconditioning the Lube Relief Valve

Reconditioning the Cooler Relief Valve

Reconditioning the Clutch Pedal Valve

Replacing the Temperature and Pressure Sending Units

Group 15: Gear Transmission

SyncroPlus Transmission, Gear Transmission - Reconditioning (Summary of References)

Special or Essential Tools

Specifications

Gear Transmission - Sectional View

Disassembling the Gear Transmission

Reconditioning the Gear Transmission

Preparation for Installing the Gear Transmission

Reconditioning the Shift Cover

Adjusting the Gear Transmission Shift Mechanism

Adjusting the Neutral Start Switch

Section 51: Power Reverser

Group 00: Removal and Installation of Power Reverser Module

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Power Reverser Module

Installing the Power Reverser Module

Removing and Installing the Gear Transmission

Group 05: Transmission Shift Controls

Power Reverser Shift Units - Reconditioning (Summary of References)

Specifications

Reconditioning the Gear Shift Mechanism

Reconditioning the Range Shift Mechanism

Reconditioning the Forward/Reverse Control

Checking and Adjusting the Shift Mechanisms/Linkages

Adjusting the Reverse Drive Lever

Adjusting the Reverse Drive Linkage

Adjusting the Clutch Pedal

Group 10: Power Reverser Module

Power Reverser Transmission, Power Reverser Module - Reconditioning (Summary of References)

Special or Essential Tools

Specifications

Power Reverser Module-Sectional View

Components of Power Train

Removing the Disk Brake

Reconditioning the Disk Brake

Installing the Disk Brake

Removing the Clutch and Planetary Carrier

Reconditioning the Clutch and Planetary Carrier

Installing the Clutch and Planetary Carrier

Removing the Transmission Oil Pump

Reconditioning the Transmission Oil Pump

Installing the Transmission Oil Pump

Valves and Other Hydraulic Components

Reconditioning the Pressure-Regulating Valve

Reconditioning the Cooling Pilot Valve

Reconditioning the Clutch Cooling Valve

Reconditioning the Engagement Override Valve

Reconditioning the Filter Relief Valve

Reconditioning the Cooler Relief Valve

Reconditioning the Lube Relief Valve

Reconditioning the Sump Valve

Reconditioning the Accumulator Piston

Reconditioning the Forward/Reverse Valve

Reconditioning the Fwd/Rev Cooling Control Valve

Reconditioning the Modulator Valve

Reconditioning the Connecting Valve

Reconditioning the Clutch Pedal Valve

Replacing the Temperature and Pressure Sending Units

Replacing the Oil Filter

Replacing the Neutral Start Switch

Group 15: Gear Transmission

Power Reverser Transmission, Gear Transmission - Reconditioning (Summary of References)

Special or Essential Tools

Specifications

Gear Transmission-Sectional View

Disassembling the Gear Transmission

Reconditioning the Gear Transmission

Preparation for Installing the Gear Transmission

Reconditioning the Shift Cover

Adjusting the Shift Mechanism on the Gear Transmission

Section 55: PowrQuad Transmission

Group 00: Removal and Installation of Components

Special or Essential Tools

Specifications

Removing the PowrQuad Transmission

Installing the PowrQuad Transmission

Removing Creeper Transmission

Installing Creeper Transmission

Removing the Range Transmission

Installing the Range Transmission

Group 05: Transmission Shift Controls

PowrQuad Transmission Shift Units-Reconditioning (Summary of References)

Specifications

Gear Shift Linkage, Reconditioning (Reverser Control on Steering Column)

Range Shift Linkage, Reconditioning (Reverser Control on Steering Column)

Reconditioning the Reverser Control (on Steering Column)

Adjusting the Reverse Drive Lever (Reverser Control on Steering Column)

Adjusting the Reverse Drive Linkage

Checking and Adjusting the Shift Mechanisms/Linkages (Reverser Control on Steering Column)

Adjust the Clutch Pedal (PowrQuad Transmission)

Group 10: PowrQuad Module

PowrQuad, Transmissions-Summary of References

Special or Essential Tools

Specifications

Transmission Components

Replacing the Neutral Start Circuit (with Mech. Actuated PowrQuad Module)

Replace Temperature Sensor and Pressure Switches

Removing and Installing the Oil Filter Housing

Removing and Installing the Front Valve Housing

Removing and Installing the Valves in the Front Valve Housing

Removing and Installing the Front Transmission Cover

Removing and Installing the Valves in the Front Transmission Cover

Removing and Installing the Shift Valve Housing (with Mech. Actuated PowrQuad Module)

Removing and Installing the Valves in the Shift Valve Housing (with Mech. Actuated PowrQuad Module)

Removing the Transmission Oil Pump

Reconditioning the Transmission Oil Pump

Installing the Transmission Oil Pump

Removing the Gear-Shift Planetary Drive

Repairing the Gear-Shift Planetary Drive

Install Gear-Shift Planetary Drive

Removing the B1 Brake Housing

Reconditioning the B1 Brake

Installing the B1 Brake Housing

Removing the B2-B3 Brake Housing

Reconditioning the B2 Brake

Reconditioning the B3 Brake

Installing the B2-B3 Brake Housing

Removing the C4 Clutch

Reconditioning the C4 Clutch

Installing the C4 Clutch

Removing the Reverse Brake

Reconditioning the Reverse Brake

Installing the Reverse Brake

Removing the Forward Clutch with Planetary Drive (Forward/Reverse)

Recondition Forward Clutch with Planetary Drive (Forward/Reverse)

Installing the Forward Clutch with Planetary Drive (Forward/Reverse)

Replacing the Output Shaft

Group 15: Creeper Transmission

Creeper Transmission-Reconditioning (Summary of References)

Specifications

Removing the Creeper Transmission

Reconditioning the Creeper Transmission

Installing the Creeper Transmission

Reconditioning the Shift Cover

Group 25: Range Transmission

Range Transmission-Reconditioning (Summary of References)

Specifications

Range Transmission - Sectional View

Removing the Range Transmission

Reconditioning the Range Transmission

Installing the Range Transmission

Reconditioning the Shift Cover

Section 56: Drive System

Group 00: Removal and Installation of Components

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the FWD Clutch

Installing the FWD Clutch

Removing the Differential Housing

Installing the Differential Housing

Removing the Final Drives

Installing the Final Drives

Removing the Rear PTO

Installing the Rear PTO

Removing the Front PTO

Installing the Front PTO

Group 05: U-Jointed Shafts and Torsion Damper

Summary of References (U-Jointed Shafts and Torsion Damper)

Special Tools

Use of Special Tool KJD10426

Specifications

Removing the U.j. Shaft (FWD)

Reconditioning the U.j. Shaft (FWD)

Installing the U.j. Shaft (FWD)

Removing the U.j. Shaft (Engine)

Removing and Installing the Ring-Shaped Cooler

Removing the Torsion Damper

Installing the Torsion Damper

Installing Engine U.J. Shaft

Group 10: Front-Wheel Drive Clutch

Front-Wheel Drive Clutch - Reconditioning (Summary of References)

Special Tools

Other Material

Specifications

Disassembling the Front Wheel Drive Clutch

Front-Wheel Drive Clutch - Exploded View

Assembling the Front-Wheel Drive Clutch

Group 15: Differential

Differential - Reconditioning (Summary of References)

Specifications

Removing the Differential

Disassembling the Differential

Differential - Exploded View

Assembling the Differential

Installing the Differential

Group 20: Hydraulic Pump Drive

Specifications

Reconditioning the Hydraulic Pump Drive

Adjusting the Hydraulic Pump Drive

Group 25: Final Drives

Special or Essential Tools

Specifications

Reconditioning the Final Drives

Group 30: Rear PTO

Rear PTO Options - Summary of References

Special Tools

Dealer-Fabricated Special Tools

Other Material

Specifications

Replacing the Output Shaft Seal Ring

Changing the O-Ring on Reversible PTO

Removing the PTO Clutch

Reconditioning the PTO Clutch

Installing the PTO Clutch

Reconditioning the PTO Brake

Disassembling the PTO Drive Train

Reconditioning the Output Shaft (540/1000 rpm Reversible)

Reconditioning the Countershaft (540/1000 rpm)

Assembling the PTO Drive Train

Adjusting Taper Roller Bearing at Output Shaft

Adjusting the Taper Roller Bearing of the Countershaft

Installing the Support and Adjusting the Taper Roller Bearings

Installing the PTO Housing

Removing the PTO Modulating Valve

Reconditioning the PTO Modulating Valve

Installing the PTO Modulating Valve

Repairing the Solenoid Valve

Replacing the PTO Speed Sending Unit

Group 35: Front PTO

Front PTO - Reconditioning (Summary of References)

Special or Essential Tools

Other Material

Specifications

General Repair Procedures

Reconditioning the Solenoid Valve

Reconditioning the PTO Modulating Valve

Replacing the Front PTO Speed Sending Unit (B58)

Cleaning and Replacing the Filter

Reconditioning the Pressure-Regulating Valve

Checking the Cooler Relief and Filter By-Pass Valves

Inspecting the Check Valves

Removing and Installing the Valve Plate

Front PTO - Sectional View

Disassembling the Front PTO

Reconditioning the Oil Pump

Reconditioning the PTO Clutch

Reconditioning the PTO Brake

Reconditioning the Intermediate Gear Shaft (PTO Rotating Counterclockwise)

Reconditioning the Drive Shaft

Assembling the Front PTO

Group 40: Front Implement Drive

Front Implement Drive (Summary of References)

General Information

Special Tools

Specifications

Summary of Torques

Preliminary work

Removing and Installing the Drive Shaft Adapter

Removing and Installing the Drive Shaft

Section 60: Steering and Brakes

Group 05: Hydrostatic Steering

Hydrostatic Steering (Summary of References)

Special Tools

Specifications

Preliminary Work

Disconnect/Connect Steering or Brake Hoses

Steering Valve - Removal

Disassembling the Steering Valve

Exploded View of Steering Valve

Assembling the Steering Valve

Adjusting the Shock Valves

Steering Wheel and Column

Recondition the Steering Column

Steering Valve - Installation

Group 10: Steering Cylinders

Steering Cylinder (Summary of References)

General Information

Special or Essential Tools

Specifications

Removing the Steering Cylinder

Disassembling the Steering Cylinder

Assembling the Steering Cylinder

Installing the Steering Cylinder

Group 15: Brake Valve

Specifications

Brake Valve

Group 20: Rear Brakes

Summary of References (Rear Brakes)

Special or Essential Tools

Specifications

Removing the Rear Brakes

Installing the Rear Brake

Checking Brake Pistons for Return Movement and Leakage

Final assembly

Bleeding the Brakes

Section 70: Hydraulic System

Group 05: Controls

Specifications

Selective Control Valves - Removing and Installing the Actuating Elements

Selective Control Valves - Adjusting the Bowden Cable

Remove and Install Multifunction Lever (Shift Console)

Adjust the Multifunction Lever (Shift Console)

Group 10: Hydraulic Pump

Other Material

Specifications

Self-Manufactured Special Tools

Repair Instructions

Removing the Hydraulic Pump

Exploded View

Repairing the Hydraulic Pump

Removing the Installation Plate

Changing the Lube Priority Valve

Installing the Installation Plate

Installing the Hydraulic Pump

Group 15: Valves

Reconditioning the Valves - Summary of References

Special or Essential Tools

Special Tools (Dealer Fabricated)

Specifications

Hydraulic System - General Instructions on Safety and Repair

Direct Control of Rockshaft

Rockshaft Valve (Narrow Version) - Removal and Installation of Spacer Housing

Removing the Rockshaft Valve

Recondition the Rockshaft Valve

Rockshaft Valve - Depth to Which Raising and Lowering Valves are Screwed In

Rockshaft Valve - Removing and Installing the Stepper Motor

Rockshaft Valve - Centering the Stepper Motor

Installing the Rockshaft Valve

Removing Main Block

Reconditioning the Main Block (PC Hydraulic System)

Installing the Main Block

Reconditioning the Hydraulic Oil Filter

Power Beyond Valve-Exploded View

Connecting the Power Beyond Valve

Converting the Power Beyond Valve

Group 20: Rockshaft

Special or Essential Tools

Other Material

Specifications

Rockshaft - Removing and Installing the Electronic Control Unit

Rockshaft - Removing and Installing the Position Sensor and Toothed Segment

Rockshaft - Removing and Installing the Rockshaft

Rockshaft - Removing the Rockshaft Cylinders

Rockshaft - Reconditioning the Rockshaft Cylinders

Rockshaft - Installing the Rockshaft Cylinders

Rockshaft - Removing and Installing the Draft Sensors and Draft Link Bearing Pins

Group 25: Selective Control Valves and Couplers

Special Tools (Dealer Fabricated)

Other Material

Specifications

Reconditioning the Selective Control Valves and Couplers - Summary of References

Reconditioning the Selective Control Valves and Couplers - General Instructions on Safety and Reconditioning

SCV Identification

Arrangement of the Shuttle Valves

Removing the Selective Control Valves

Series 101 Selective Control Valve - Exploded View

Series 101 Selective Control Valve - Reconditioning

Series 201/301 Selective Control Valves - Replacing the Control Knobs

Series 201/301 Selective Control Valves - Inspecting the Check Valves

Series 201/301 Selective Control Valves - Inspecting the Inlet Check Valve and Metering Valve

Series 201 Selective Control Valves - Reconditioning

Series 301 Selective Control Valves - Inspecting the Pressure Compensator Valve

Series 301 Selective Control Valves - Reconditioning

Installing the Selective Control Valves

Selective Control Valves - Installing the Endplate

Selective Control Valves - Reconditioning the Couplers

Group 30: Independent Control Valve

Reconditioning Independent Control Valves - Summary of References

Other Material

Specifications

Removing the Independent Control Valve (M-ICV)

Reconditioning the Independent Control Valve (M-ICV)

Independent Control Valves - Reconditioning the Inlet Plate

Assembling the Independent Control Valve (M-ICV)

Installing the Independent Control Valve (M-ICV)

Section 80: Misellaneous

Group 00: Removal and Installation of Components

Special or Essential Tools

Dealer-Fabricated Special Tools

Specifications

Removing and Installing the Main Frame (Summary of References)

Removing the Main Frame

Installing the Main Frame

Removing and Installing the Front Axle or Front-Wheel Drive Axle (Summary of References)

Removing the Front Axle

Installing the Front Axle

Removing the Front-Wheel Drive Axle

Installing the Front-Wheel Drive Axle

Removing and Installing the Front Axle Support (Summary of References)

Removing the Front Axle Support

Installing the Front Axle Support

Group 05: Main Frame

Specifications

Reconditioning the Main Frame

Group 10: Front Axle

Special or Essential Tools

Specifications

Front Axle - Reconditioning (Summary of References)

Removing the Front Axle

Reconditioning the Front Axle

Installing the Front Axle

Checking and Adjusting Toe-In

Group 15: Front and Rear Wheels

Front Wheels, Rear Wheels and Fenders - Reconditioning (Summary of References)

Special or Essential Tools

Specifications

Pivoting Front Fender

Removing the Front and Rear Wheels

Reconditioning the Front and Rear Wheels

Installing the Front and Rear Wheels

Group 20: Trailer Mounting and Swinging Drawbar

Tightening Torque On Center Link Bracket

Tightening Torques On Swinging Drawbar

Tightening Torques On High-Clearance Drawbar

Adjusting the High-Clearance Drawbar

Adjusting the Retaining Strap

Section 90: Operator's Cab

Group 00: Removal and Installation of Components

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Operator's Cab / Open Station, Tilting or Removing and Installing

Tilting the Operator's Cab Upward

Tilting the Operator's Cab Downward

Removing the Operator's Cab

Installing the Operator's Cab

Removing the Open Operator's Station

Installing the Open Operator's Station

Checking and Adjusting the Shift Mechanisms/Linkages

Group 05: Controls and Instruments

Controls and Instruments (Summary of References)

Disconnecting Electrical Circuit

Instructions when Replacing a Control Unit

Replacing Bulbs on the Instrument Unit

Replacing a BCU Control Unit

Replacing a BCU Control Unit (Tractors without Cab)

Replacing Instrument Unit

Replacing Terminating BUS Resistors

Replace Operation Unit of Hitch

Group 10: Air-Conditioning System

Air-Conditioning System (Summary of References)

Special Tools

Specifications

Torques for Tightening Refrigerant Hoses

Safety At Work

Handling Refrigerant

In An Emergency

Safety Equipment

Storage of Refrigerant Containers

R134A Refrigerant

Important Note

Discharging the System

Evacuating the System

Filling With Refrigerant Oil

Instructions for Starting Up the DENSO Air-Conditioning Compressor

Filling the System

Topping Up a Partly Discharged System

Leak Test

Removing the Compressor

Checking Level in the Compressor

Disassembling the Compressor Clutch

Checking Clutch Hub Clearance

Checking the Compressor Manifold

Installing the Compressor

Removing and Installing the Condenser

Removing and Installing the Receiver-Drier

Removing and Installing the Evaporator and Expansion Valve

Arrangement of Condensation Water Drain Hoses

Condensation Water Drainage (upgraded version)

Removing the Heater/Evaporator Housing

Removing and Installing the Thermostat Switch

Removing and Installing the High/Low Pressure Switch

Group 15: Heating System

Heating System

Group 20: Seats

Seats (Summary of References)

Specifications

Comfort Seat MSG85

Super Comfort Seat MSG83

Exploded View of the Instructional Seat

Group 25: Operator's Cab

Operator's Cab (Summary of References)

Removing Cab Frame

Torques for Hardware on Platform Mounting (2-Post ROPS, Standard Version)

Cab Mounting Torques

Removing the Outer Roof

Removing and Installing the Windshield

Removing and Installing the Rear Window

Removing and Installing the Roof Hatch

Installing Door Lock

Adjusting Windshield and Rear Window Contact Pressure

Operator's Cab Door Removal and Installation

Removing Inner Roof Trim

Section 99: Special Tools

Group 05: Special Tools (Dealer-Fabricated)

DFLX2 - Suspension Device

DFLX3 – Suspension Device for PowrQuad Module

DFLX13 - Holding Device

Suspension Eyes for Operator's Cab

Holding Tool

DFLX16 - Wooden Block

DFRW79 – Piston Holding Tool

DFLX24 - Seal Installer

DFLX25 – Driver

DFLX17 - Assembly and Guide Mandrels

Turning Device

Bushing

DFLX27 – Driver

DFLX23 – Socket Wrench Insert

DFLX21 - Special Wrench

Group 10: Special Tools (available from the dealer)

D01019AA - Manually operated hydraulic pump

D01042AA – Load-Positioning Sling

D05007ST – Tractor Splitting Stand

FKM10002 - Universal pressure test kit

FKM10409 - Battery load tester

FKM10444 - Leak detector

FKM10470 - Pressure measuring system (stage 1)

FKM10471 - Pressure measuring system (stage 2)

FKM10472 - Through-flow measuring system

JDE83 – Flywheel Turning Tool

JDG19 – Special Mounting Brackets

JDG23 – Lifting Sling

JDG749 - 1.30 m (52 in.) Torque Extension

JDG750 – Swivel Socket

JDG820 – Flywheel Turning Tool

JT02044 – Support Stand

JT02153 - Clamp-on current probe

JT03248 - Fitting

JT05723 – Medium-Duty Rear Tractor Splitting Stand

JT05724 – Medium-Duty Front Tractor Splitting Stand

JT05725 – Universal Support Stand

JT05791A - Multimeter

KJD10293 – Disconnecting Tool

KJD10173 – Shaft Puller

KJD10178D – Cab Tilting Device

KJD10292 - Diagnostic Harness

KJD10501 - Disconnecting Tool-Kit

RE200690 - Performance Monitor

RE37996 - Adjusting tool

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