Complete Repair Service Technical Manual for John Deere Tractors Models 6415 and 6615, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere Tractors Models 6415 and 6615 (South America) 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.

tm8130 - 6415 and 6615 Tractors — Repair Technical Manual.pdf
tm8130 - 6415 and 6615 Tractors — Repair Technical Manual.epub

Total Pages: 1,194 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Safety
      Safety Regulations
   General Information
      Specifications
      Adjusting
      Predelivery Inspection
   Engine
      Removing and Installing Engine
   Fuel Systems, Air Intake, Cooling and Exhaust
      Speed Control Link
      Fuel System
      Air Intake System
      Cooling System
      Exhaust System
   Electrical System
      Connectors
      Wiring Harnesses
      Charging Circuit
      Starter Motor Circuit
      Fuses, Relays and Switches
      Monitoring Systems
      Electrical Components
   SyncroPlus Transmission
      Removing and Installing Transmission Components
      Transmission Selectors Control
      Perma Clutch Module II
      Gearbox
      Creeper Transmission
      Range Box - 20 Series
   PowrQuad Transmission
      Removing and Installing PowrQuad Module
      PowrQuad Module
   Drive Systems
      Removing and Installing Component
      U-Joint Shafts and Torsional Damper
      Front-Wheel Drive Clutch
      Differential
      Hydraulic Pump Drive
      Final Drives
      PTO Options
   Steering and Brakes
      Hydrostatic Steering
      Brake Valve
      Rear Brakes
   Hydraulic System
      Rockshaft Controls
      Hydraulic Pump and Charge Pump (PFC Hydraulic System)
      Hydraulic Pump (PC Hydraulic System)
      Valve Block
      Rockshaft
      Selective Control Valves and Quick Couplers
   Miscellaneous
      Removing and Installing Components
      Main Chassis
      Front Wheels, Rear Wheels and Fenders
      Center Link Bracket and Swinging Drawbar
   Operator's Cab
      Removing and Installing Components
      Air Conditioning System
      Heating System
      Operator's Cab
   Special Tools (Dealer-Fabricated)
      Special Tools (Dealer-Fabricated)

tm8130 - 6415 and 6615 Tractors — Repair Technical Manual

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Regulations

Live With Safety

Recognize Safety Information

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Handle Batteries Safely

Prevent Acid Burns

Prepare for Emergencies

Remove Paint Before Welding or Heating

Avoid High-Pressure Fluids

Engine Coolant

Prevent Machine Runaway

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Wear Protective Clothing

Practice Safe Maintenance

Park Machine Safely

Use Proper Lifting Equipment

Support Machine Safely

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Use Proper Tools

Service Tires Safely

Safe Servicing of Front-Wheel Drive

Use Seat Belt Properly

Keep ROPS Installed Properly

Dispose of Waste Properly

Section 10: General Information

Group 05: Specifications

Engine

Cooling System

Injection Pump (Lucas)

Air Intake System

PTO

Clutch

SyncroPlus SYNCROPLUS is a registered trademark of the Deere & Company Transmission

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission

Creeper Transmission

Hydraulic System

Brakes

Tires

Tractor Weight in Standard Configuration in kg (lb)

Dimensions

Electrical System

Capacities

Transmission and Hydraulic Oil

Front Wheel Drive Axle Oil

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Hydraulic System Unified Inch Fitting Torques

Hydraulic system metric fitting torques

Identification Number

Product Identification Number

Engine Serial Number

Transmission Serial Number SYNCROPLUS SYNCROPLUS is a registered trademark of the Deere & Company

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission Serial Number

Front Wheel Drive Serial Number

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Differential Serial Number

Rear Final Drives Serial Number

Cab Serial Number

Operator's Station Serial Number

Sub-Assembly Serial Numbers

Group 10: Adjustment

Use of High-Pressure Washers

Preliminary Engine Test

Removing and Cleaning Main Air Filter Element

Checking Air Filter Safety Element

Installing Main Filter Element

Checking for Leaks in Air Intake System Connections

Checking for Plugging of Crankcase Vent Hose

Cleaning Radiator Screen

Checking Expansion Tank Cap

Checking for Leaks in Radiator

Checking Engine Thermostat

Checking Fuel Filter

Cleaning Water Separator

Run the Engine until it is Warm, and Check Engine Speeds

Checking Fuel Injection Pump Adjustment

Checking Engine Speed Control Link Adjustment

Cleaning Battery, Cables and Battery Box with a Clean Cloth

Checking Neutral Start Circuit

Checking Starter Motor

Checking Lighting Circuit

Final Engine Checks

Checking Tractor Operation

Group 15: PRE-DELIVERY INSPECTION

Predelivery Inspection

Section 20: Engine

Group 00: Removing and Installing Engine

Special or Essential Tools

Specifications

Removing Engine

Installing Engine

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

Group 05: Speed Control Link

Hand Throttle Lever and Accelerator Pedal Adjustment

Speed Control Link Adjustment

Hand Throttle Lever - Exploded View

Accelerator Pedal, with Mechanical Speed Control

Accelerator Pedal Adjustment

Group 10: Fuel System

General information

Special Tool (Dealer Fabricated)

Removing Fuel Tank

Installing Fuel Tank

Replacing Fuel Gauge Sensor Unit

Replacing Fuel Transfer Pump

Replacing Fuel Filter

Bleeding Fuel System

Group 15: Air Intake System

General information

Air Filter - Exploded View

Replacing Air Filter Restriction Sensor

Group 20: Cooling system

General information

Specifications

Removing Radiator

Installing Radiator

Replacing Fan

Removing and Installing Expansion Tank

Removing and Installing Thermostat

Filling Cooling System with Coolant

Releasing Drive Belt Tension

Replacing Drive Belt

Replacing Drive Belt Tensioner

Repairing Fan Console

Group 30: Exhaust System

General information

Specifications

Exhaust to Upper Right-Hand Side

Section 40: Electrical System

Group 05: Connectors

Special Tools

General

Use of 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 Boxes on Tractors with Operator's Cab

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

Group 10: Harnesses

Disconnecting Electrical Circuits

Location of Ground Points

Removing and Installing Wiring Harness W01 — Power Supply

Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Open Operator's Station)

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

Removing and Installing Wiring Harness W03

Removing and Installing Wiring Harness W04 — Headlights

Removing and Installing Wiring Harness W08 — Open Operator's Station

Removing and Installing Wiring Harness W09 — Hood (Open Operator's Station)

Removing and Installing W19 Wiring Harness — Cab Roof

Removing and Installing W26 Wiring Harness — Fan and Air Conditioning

Removing and Installing Wiring Harness W28 — Front End of Transmission (Open Operator's Station)

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

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

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

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

Work Lights and Turn Signal Lights Wiring Harness (Tractor without Cab)

Windshield Wiper Harness - Rear

Group 15: Charging Circuit

Special Tools

Specifications

Replacing Alternator

Disconnecting Electrical Circuits

Removing/Installing Alternator

Removing/Installing Alternator Pulley

Group 20: Starter Motor Circuit

Specifications

Repairing Starter Motor

Disconnecting Electrical Circuits

Removing and Installing the Starter Motor

Group 25: Fuses, Relays and Switches

Note

Special Tools

Specifications

Removing Hood Covers

Disconnecting Electrical Circuits

Fuse and Relay Box - Cab Tractors

Fuse and Relay Box - Tractors with Open Operator Station

Replacing Main Fuses

Replacing Starter Motor Relay

Replacing Starter Switch

Replacing Brake Switches

Replacing Light Switch

Replacing Full/Low Beam Switch

Replacing Work Light Switches

Replacing Hazard Warning Light Switch

Replacing Turn Signal Switch

Replacing Horn Switch

Replacing Windshield Wiper and Windshield Washer Switch

Replacing Front-Wheel Drive Switch

Replacing Fan Switch

Replacing Differential Lock Switch

Replacing Rockshaft Remote Control Switch

Group 30: Monitoring Systems

Note

Note

Disconnecting Electrical Circuits

Replacing Engine Speed Sensor Unit (B01)

Replacing Engine Oil Pressure Sensor Unit (B04)

Replacing Coolant Temperature Gauge Sensor Unit (B08)

Group 40: Electrical Components

Note

Special Tools

Specifications

Disconnecting Electrical Circuits

Replacing Socket of 7-Terminal Power Outlet

Replacing Service Socket

Removing Windshield Wiper Motor

Adjusting Headlights

Adjusting Cab Frame Lights

Lights with Halogen Bulbs

Section 50: SyncroPlus Transmission

Group 00: Removing and Installing Transmission Components

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing Clutch Housing

Installing Clutch Housing

Removing Transmission

Installing Transmission

Group 05: Transmission selectors control

Specifications

Reconditioning Gear Shift Mechanism

Reconditioning Range Shift Lever Mechanism

Checking and Adjusting Shift Units

Adjusting the Clutch Pedal

Group 10: Perma Clutch Module II

Special or Essential Tools

Specifications

Removing Clutch

Repairing Clutch

Installing Clutch

Removing Transmission Oil Pump

Repairing Transmission Oil Pump

Installing Transmission Oil Pump

Valves and Other Hydraulic Components

Repairing Engagement Override Valve (EOV)

Repairing Clutch Cooling Valve

Repairing Cooling Pilot Valve

Repairing Bypass Valve

Repairing Pressure Regulating Valve

Repairing Lube Relief Valve

Repairing Cooler Relief Valve

Repairing Clutch Pedal Valve

Replacing Pressure and Temperature Sensor Units

Group 15: Gearbox

Special or Essential Tools

Specifications

Transmission—Cross-Sectional View

Disassembling Creeper Transmission

Repairing Transmission

Preparing the Installation of the Transmission

Repairing Shift Cover

Adjusting Gear Shift Actuating Mechanism

Adjusting Neutral Start Switch

Group 20: Creeper Transmission

Specifications

Preparations

Removing Creeper Transmission

Disassembling Creeper Transmission

Installing Creeper Transmission

Shifting Mechanism — Cross-Sectional View

Installing Gear Shift Elements

Repairing Creeper Transmission Gearbox Cover

Final Assembly

Installing Creeper Transmission

Group 30: Range Box — 20 Series

Specifications

Range box—Cross-Sectional View

Removing Range Box

Servicing Range Box

Installing Range Box

Servicing Shift Cover

Section 55: PowrQuad Transmission

Group 00: Removing and Installing PowrQuad Module

Special Tools

Special Tool (Own Fabrication)

Specifications

Separating PowrQuad Housing

Installing PowrQuad Housing

Group 10: PowrQuad Module

Special or Essential Tools

Service Equipment and Tools

Other Materials

Specifications

Transmission Components

Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)

Removing and Installing Oil Filter Base

Replacing Oil Filter

Removing and Installing Front Valve Housing

Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)

Removing and Installing Transmission Front Cover

Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)

Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)

Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)

Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)

Removing Transmission Oil Pump

Servicing Transmission Oil Pump

Installing Transmission Oil Pump

Removing Planetary Drive Gears

Repairing Planetary Drive Gears

Installing Planetary Drive Gears

Removing B1 Brake Housing

Repairing Brake B1

Installing B1 Brake Housing

Removing B2-B3 Brake Housing

Reconditioning B2 Brake

Reconditioning B3 Brake

Installing B2-B3 Brake Housing

Removing C4 Clutch

Reconditioning C4 Clutch

Installing C4 Clutch

Removing Reverse Brake

Servicing Reverse Brake

Installing Reverse Brake

Removing Forward Clutch with Planetary Drive (Forward/Reverse)

Servicing Forward Clutch with Planetary Drive (Forward/Reverse)

Installing Forward Clutch with Planetary Drive (Forward/Reverse)

Replacing Output Shaft

Section 56: Drive Systems

Group 00: Removing and Installing Component

Special or Essential Tools

Special Tools (Dealer Fabricated)

Specifications

Removing Front-Wheel Drive Clutch

Installing Front-Wheel Drive Clutch

Removing Differential Housing

Installing Differential Housing

Removing Final Drive

Installing Final Drive

Removing PTO

Installing PTO

Group 05: U-Jointed Shafts and Torsional Damper

Special Tools

Using KJD10426 Special Tool

Specifications

Removing MFWD Universal-Joint Drive Shaft

Repairing MFWD Universal-Joint Drive Shaft

Installing MFWD Universal-Joint Drive Shaft

Removing Engine Universal-Joint Drive Shaft

Removing Torsional Damper

Replacing Torsional Damper Bearings

Installing Torsional Damper

Installing Engine Universal-Joint Drive Shaft

Group 10: Front-Wheel Drive Clutch

Special or Essential Tools

Other Material

Specifications

Disassembling Front-Wheel Drive Clutch

Front-Wheel Drive Clutch — Exploded View

Mounting Front-Wheel Drive Clutch

Group 15: Differential

Specifications

Removing Differential

Disassembly of Differential

Differential — Exploded View

Assembling the differential

Installing Differential

Group 20: Hydraulic Pump Drive

Special Tools

Specifications

Repairing Hydraulic Pump Drive

Adjusting Hydraulic Pump Drive

Group 25: Final Drives

Special or Essential Tools

Specifications

Repairing Final Drive

Group 30: PTO Options

Special Tools

Special Tools (Dealer Fabricated)

Other Material

Specifications

Replacing Output Shaft Retainer

Replacing O-Ring of Reversible PTO

Removing PTO Clutch

Repairing 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)

Mounting PTO Transmission

Adjusting Output Shaft Cone Bearing

Adjusting Countershaft Cone Bearing

Installing Support and Adjusting Cone Bearings

Installing PTO Housing

Removing PTO Modulating Valve

Reconditioning PTO Modulating Valve

Installing PTO Modulating Valve

Repairing Solenoid Valve

Section 60: Steering and Brakes

Group 05: Hydrostatic Steering

Special Tools

Specifications

Preliminary Tasks

Disconnecting/Connecting Steering or Brake Hoses

Steering Valve - Removing

Assembling Steering Valve

Exploded View of Steering Valve

Assembling the Steering Valve

Adjusting Shock Valves

Steering and Steering Column

Reconditioning Steering Column

Steering Valve - Installation

Group 15: Brake Valve

Special Tools

Specifications

Brake Valve

Group 20: Rear Brakes

Special or Essential Tools

Specifications

Removing the Rear Brakes

Installing Rear Brake

Checking Brake Piston Return Movement and Leaks

Final assembly

Bleeding Brakes

Section 70: Hydraulic System

Group 05: Rockshaft Controls

Specifications

Selective Control Valves — Removing and Installing Actuating Elements

Selective Control Valves — Adjusting Bowden Cable

Group 10: Hydraulic Pump and Charge Pump (PFC Hydraulic System)

Other Material

Specifications

Removing and Installing Charge Pump

Charge Pump Repair

Charge Pump - Checking Lube Oil Valve

Hydraulic Oil Reservoir — Restrictor

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

Hydraulic Pump — Reconditioning Pressure-and-Flow Controller

Removing and Installing the Hydraulic Pump

Repairing Hydraulic Pump

Group 11: Hydraulic Pump (PC Hydraulic System)

Other Material

Specifications

Removing Hydraulic Pump

Hydraulic Pump - Removing Mounting Plate

Replacing Lube Priority Valve

Hydraulic Pump - Installing Mounting Plate

Installing Hydraulic Pump

Group 15: Cam Lobe Motor

Special Tools

Special Tools (Dealer Fabricated)

Specifications

Hydraulic System — General Safety and Repair Instructions

Direct Rockshaft Control

Rockshaft Valve (Narrow Version) — Removing and Installing Spacer

Removing Rockshaft Valve

Installing Rockshaft Valve

Repairing Rockshaft Valve

Rockshaft Valve — Depth of Raising and Lowering Valves

Rockshaft Valve — Removing and Installing Stepper Motor

Rockshaft Valve — Centering Stepper Motor

Removing Priority Valve (PFC Hydraulic System)

Removing Priority Valve (PC Hydraulic System)

Removing Priority Valve (PC Hydraulic System)

Installing Priority Valve (PC Hydraulic System)

Reconditioning Hydraulic Oil Filter

Group 20: Rock Shaft

Special or Essential Tools

Dealer Fabricated Special Tools

Other Material

Specifications

Rockshaft — Removing and Installing of Position Sensor and Toothed Segment

Rockshaft — Removing and Installing Rockshaft

Rockshaft — Removing Rockshaft Cylinders

Rockshaft — Reconditioning Rockshaft Cylinders

Rockshaft — Installing Rockshaft Cylinders

Rockshaft — Removing and Installing Draft Sensors and Draft Link Bearing Pins

Group 25: Selective Control Valves and Quick Couplers

Special Tools

Special Tools (Dealer Fabricated)

Other Material

Specifications

Reconditioning Selective Control Valves and Quick Couplers — General Safety and Reconditioning Instructions

Installing Shuttle Valves

Installing Shuttle Valves (Narrow Version)

Removing Selective Control Valves

100 Series Selective Control Valve

Disassembling, Inspecting and Assembling 101 Series Selective Control Valve

Disassembling, Inspecting and Assembling 300 Series Selective Control Valve (SCV)

Installing Selective Control Valves

Adjusting Pressure with Selective Control Valves

Quick Couplers — Service

Mounting Quick Coupler

Section 80: Others

Group 00: Remove and Install Components

Special or Essential Tools

Special Tools (Dealer Fabricated)

Specifications

Removing Main Chassis

Installing Main Frame

Removing Front-Wheel Drive Axle

Installing Front-Wheel Drive Axle

Group 05: Main Frame

Specifications

Repairing Main Chassis

Group 15: Front Wheels, Rear Wheels and Fenders

Special or Essential Tools

Specifications

Installing Front Fenders

Removing Front and Rear Wheels

Reconditioning Front and Rear Wheels

Installing Front and Rear Wheels

Group 20: Center Link Bracket and Swinging Drawbar

Specifications

Checking Swinging Drawbar Wear

Installing Center Link Bracket

Swinging Drawbar

Adjusting Retention Rod

Section 90: Operator's Cab

Group 00: Removing and Installing Components

Special Tools

Special Tools (Dealer Fabricated)

Specifications

Swinging Up Operator's Cab

Swinging Down Operator's Cab

Removing Operator's Cab or Platform

Installing Operator's Cab or Platform

Checking and Adjusting Shift Units

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

R134a Refrigerant

Important

Other Material

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 Compressor Clutch

Checking Clutch Hub Separation

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 99: Special Tools (Dealer-Fabricated)

Group 05: Special Tools (Dealer-Fabricated)

Suspension Device

Suspension Device

Retaining Device

Operator's Cab Lifting Loop

Retention Tool

Wooden Block

DFRW79 - Piston Retainer Tool

Socket Wrench Insert

Retainer Installer

Retainer

Assembling and Guide Drivers

Turning Tool

Bushing

Retainer Installer

Socket Wrench Insert

Special Wrench

Quick Coupler Securing Support

Lifting Tool

John Deere Tractors Models 6415 and 6615 Repair Service Manual (TM8130)