5090R, 5100R, 5115R, 5115RH and 5125R (FT4/ Stage IIIB) Tractors Repair
REPAIR TECHNICAL MANUAL 5R Series Tractors TM143519 01DEC18 (ENGLISH)
John Deere Augusta Works
Introduction Foreword The diagnostic technical manual is written for an experienced technician. Essential tools required to perform certain type of work are identified in Section 300, and are recommended for use.
Diagnostic technical manuals are comprised of general information, checks, theory of operation, schematic and diagnostic procedures. Sections in a diagnostic technical manual help quickly identify the likely cause of routine failures. Component sections include images of the component or connector and location on the equipment.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text.
The diagnostic technical manual references component manuals and repair technical manuals. Repair technical manuals are organized for various components requiring service instruction.
CAUTION: This is the safety-alert symbol. When the symbol is shown on the equipment or in a manual, be alert to the potential for personal injury.
Both diagnostic and repair technical manuals are concise guides for specific equipment. They are on-the-job instructions containing vital information to diagnose, analyze, test, and repair the equipment. DX,DIAGTM,IFC-19-20111208
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Contents Group 05 - Steering Group 10 - Brakes
Section 10 - General Information Group 05 - Safety Group 10 - General Specifications Group 15 - Fuels and Lubricants Group 20 - Serial Number Locations
Section 70 - Hydraulics - Open Center Group 05 - Pumps and Filters Group 15 - Hitch Valve Group 20 - Rear Selective Control Valves Group 25 - Mid-Mount Selective Control Valves
Section 20 - Engine Group 05 - Engine
Section 30 - Fuel, Air Intake, Exhaust, and Cooling Group 05 - Fuel System Group 10 - Air Intake System Group 15 - Exhaust System Group 20 - Cooling System
Group 10 - Hydraulic Controls Group 15 - Rear Hitch Group 20 - Front Hitch
Group 05A - Fuses and Relays Group 05B - Ground Points Group 05C - Connectors Group 05D - Wiring Harnesses Group 05E - Electrical Components
Drive
Group 05 - Pumps and Filters Group 10 - Rear SCVs Group 25 - Mid-Mount SCV Valves
Section 72 - Hydraulics - Common
Section 40 - Electrical
Section 50 Transmissions
Section 71 - Hydraulics - Closed Center
Systems
Group 05 - Separation Group 10 - PPST Transmission Group 15 - Clutch Assembly Group 20 - Differential Group 25 - Control Valves Group 30 - Final Drive Group 35 - Rear PTO Group 40 - Front PTO Group 45 - Mechanical Front-Wheel Drive Group 50 - Suspended Front Axle Group 55 - Creeper Assembly Group 60 - Transmission Lube Pump
Section 80 - Miscellaneous
and
Group 10 - Rear Hitches Group 15 - Fenders Group 20 - Hood Group 25 - Step Assemblies Group 30 - Wheels
Section 90 - Cab and Open Operator`s Station Group 05 - Seat and Support Group 10A - Control Console Group 10B - CommandARM™ Group 20 - Cab Components Group 30 - Air Conditioning System Group 35 - Heating System
Section 99 - Special Tools Group 05 - Dealer Fabricated Tools Group 10 - Service Tools
Section 60 - Steering and Brakes
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Section 10
General Information Contents Page
Page
Service Cooling System Safely ............................ . 10-05-19
Group 05 - Safety Work In Ventilated Area ........................................ . 10-05-1 Recognize Safety Information .............................. . 10-05-1 Avoid Backover Accidents .................................... . 10-05-1 Prevent Machine Runaway................................... . 10-05-2
Wait
Before Opening High-Pressure Fuel 10-05-19 System .......................................................... .
Service Front-Wheel Drive Tractor Safely ............ . 10-05-19 Use Steps and Handholds Correctly .................... . 10-05-20
Avoid Contact with Agricultural Chemicals ............ 10-05-2
Handle Electronic Components and Brackets 10-05-20 Safely ............................................................ .
Clean Vehicle of Hazardous Pesticides................. 10-05-2
Transport Tractor Safely ....................................... . 10-05-20
Use a Safety Chain............................................... . 10-05-3
Deliver Safely ....................................................... . 10-05-20
Work in Clean Area .............................................. . 10-05-3
Servicing Electronic Control Units ........................ . 10-05-21
Decommissioning - Proper Recycling and Disposal 10-05-3 of Fluids and Components ............................ .
Welding Near Electronic Control Units ................. . 10-05-21
Avoid Harmful Asbestos Dust ............................... . 10-05-4
Keep Electronic Control Unit Connectors Clean .. . 10-05-22
Use Electronic Display Properly ............................ 10-05-4
Group 10 - General Specifications
Avoid Hot Exhaust ................................................ . 10-05-4
Regions and Country Versions............................. . 10-10-1
Clean Exhaust Filter Safely .................................. . 10-05-5
Features and Accessories.................................... . 10-10-2
Exhaust Filter Cleaning ........................................ . 10-05-6
Machine General Specifications........................... . 10-10-4
Handle Fuel Safely-Avoid Fires ............................ . 10-05-6
Drain and Refill Capacities ................................... . 10-10-4
Prepare for Emergencies...................................... . 10-05-6
Service Recommendations for O-Ring Boss 10-10-5 Fittings........................................................... .
In Case of Fire ...................................................... . 10-05-6 Handle Fluids Safely-Avoid Fires .......................... 10-05-7
Service Recommendations For Flat Face O-Ring 10-10-6 Seal Fittings .................................................. .
Avoid High-Pressure Fluids .................................. . 10-05-7
Metric Bolt and Screw Torque Values................... . 10-10-7
Use Foldable ROPS and Seat Belt Properly ......... 10-05-7
Unified Inch Bolt and Screw Torque Values ......... . 10-10-8
Avoid Static Electricity Risk When Refueling......... 10-05-8
Glossary of Terms ................................................ . 10-10-9
Install All Guards .................................................. . 10-05-8
Trademarks .......................................................... . 10-10-10
Use Proper Lifting Equipment............................... . 10-05-9 Illuminate Work Area Safely ................................. . 10-05-9 Live With Safety.................................................... . 10-05-9 Service Machines Safely ...................................... . 10-05-9 Support Machine Properly .................................... . 10-05-10 Protect Against Noise ........................................... . 10-05-10 Remove Paint Before Welding or Heating ............. 10-05-10 Park Machine Safely............................................. . 10-05-11
Group 15 - Fuels and Lubricants Alternative and Synthetic Lubricants .................... . 10-15-1 Transmission and Hydraulic Oil............................ . 10-15-1 Diesel Engine Coolant (engine with wet sleeve 10-15-2 cylinder liners) ............................................... . Operating in Warm Temperature Climates ........... . 10-15-2 John Deere COOL-GARD™ II Coolant Extender. . 10-15-3
Stay Clear of Rotating Drivelines........................... 10-05-12
Water Quality for Mixing with Coolant 10-15-4 Concentrate................................................... .
Follow Safety Instructions..................................... . 10-05-12
Testing Coolant Freeze Point ............................... . 10-15-4
Use Proper Tools .................................................. . 10-05-13
Diesel Exhaust Fluid (DEF) - Use in Selective 10-15-5 Catalytic Reduction (SCR) Equipped Engines ......................................................... .
Service Tires Safely.............................................. . 10-05-13 Keep ROPS Installed Properly ............................. . 10-05-13 Stay Clear of Rotating Drivelines........................... 10-05-14 Construct Dealer-Made Tools Safely ..................... 10-05-14 Practice Safe Maintenance................................... . 10-05-15 Understand Signal Words..................................... . 10-05-15 Replace Safety Signs ........................................... . 10-05-15 Protect Against High Pressure Spray .................... 10-05-16 Store Attachments Safely ..................................... . 10-05-16 Avoid Heating Near Pressurized Fluid Lines ......... 10-05-16 Wear Protective Clothing ...................................... . 10-05-16 Precautions for Welding ....................................... . 10-05-17
Disposal of Diesel Exhaust Fluid (DEF) ............... . 10-15-5 Refilling Diesel Exhaust Fluid (DEF) Tank............ . 10-15-5 Storing Diesel Exhaust Fluid (DEF)...................... . 10-15-6 Testing Diesel Exhaust Fluid (DEF)...................... . 10-15-6 Diesel Engine Oil Service Interval for Operation at 10-15-6 High Altitude.................................................. . Diesel Engine Oil - Interim Tier 4, Final Tier 4, 10-15-7 Stage IIIB, and Stage IV................................ . Engine Oil and Filter Service Intervals - Interim 10-15-8 Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines ......................................................... .
Service Accumulator Systems Safely.................... 10-05-17
John Deere Break-In Plus™ Engine Oil - Interim 10-15-8 Tier 4, Final Tier 4, Stage IIIB, and Stage IV. .
Handling Batteries Safely ..................................... . 10-05-17
Oil Filters .............................................................. . 10-15-8
Handle Agricultural Chemicals Safely ................... 10-05-18 TM143519 (01.12.2018)
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Page
Fuel Filters............................................................ . 10-15-9
Page
Diesel Fuel............................................................ . 10-15-10
Transmission, Steering, Brake, Hydraulic, and 10-15-15 Gear Case Oil ............................................... .
Handling and Storing Diesel Fuel .......................... 10-15-10
Oilscan™ and CoolScan™................................... . 10-15-15
Lubricity of Diesel Fuel ......................................... . 10-15-11
Group 20 - Serial Number Locations
Testing Diesel Fuel ............................................... . 10-15-11
Serial Numbers..................................................... . 10-20-1
BioDiesel Fuel ...................................................... . 10-15-12
Product Identification Number .............................. . 10-20-2
Minimizing the Effect of Cold Weather on Diesel 10-15-13 Engines ......................................................... .
Engine Serial Number .......................................... . 10-20-3
Supplemental Diesel Fuel Additives ...................... 10-15-13 Grease.................................................................. . 10-15-14
Transmission Serial Number ................................ . 10-20-4 Suspended Front Axle Serial Number.................. . 10-20-4
Mixing of Lubricants.............................................. . 10-15-14
Mechanical Front Wheel Drive (MFWD) Serial 10-20-4 Number ......................................................... .
Lubricant Storage ................................................. . 10-15-14
Cab Serial Number............................................... . 10-20-5
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5R Series Tractors
Safety
Group 05 Safety Work In Ventilated Area
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. DX,AIR-19-19990217
Recognize Safety Information
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. DX,ALERT-19-19980929
Avoid Backover Accidents
PC10857XW-UN: Avoid Backover Accidents
Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use a signal person when backing if view is obstructed or when in close quarters. Do not rely on a camera to determine if personnel or obstacles are behind the machine. The system can be limited by many factors including maintenance practices, environmental conditions, and operating range. DX,AVOID,BACKOVER,ACCIDENTS-19-20100830
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Safety
Prevent Machine Runaway
TS177-UN: Machinery Runaway
Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. DX,BYPAS1-19-19980929
Avoid Contact Chemicals
with
Agricultural
TS272-UN: Pesticide Use
CAUTION: This enclosed cab does not protect against inhaling vapor, aerosol or dust. 1. When operating in an environment where pesticides are present, wear a long-sleeved shirt, long-legged pants, shoes, and socks. 2. If pesticide use instructions require respiratory protection, wear an appropriate respirator inside the cab. 3. Wear personal protective equipment as required by the pesticide use instructions when leaving the enclosed cab:
into a treated area to work with contaminated application equipment such as nozzles which must be cleaned, changed or redirected to become involved with mixing and loading activities
TS220-UN: Harmful Pesticides
4. Before re-entering the cab, remove protective equipment and store either outside the cab in a closed box or some other type of sealable container or inside the cab in a pesticide resistant container, such as a plastic bag. 5. Clean your shoes or boots to remove soil or other contaminated particles prior to entering the cab. DX,CABS1-19-20090325
Clean Vehicle of Hazardous Pesticides
When exposed to hazardous pesticides, clean exterior and interior of vehicle daily to keep free of the accumulation of visible dirt and contamination. 1. Sweep or vacuum the floor of cab.
CAUTION: During application of hazardous pesticides, pesticide residue can build up on the inside or outside of the vehicle. Clean vehicle according to use instructions of hazardous pesticides.
2. Clean headliners and inside cowlings of cab. 3. Wash entire exterior of vehicle. 4. Dispose of any wash water with hazardous concentrations of active or non-active ingredients according to published regulations or directives. DX,CABS2-19-20010724
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5R Series Tractors
Safety
Use a Safety Chain
TS217-UN: Safety Chain
A safety chain will help control drawn equipment should it accidentally separate from the drawbar. Using the appropriate adapter parts, attach the chain to the tractor drawbar support or other specified anchor location. Provide only enough slack in the chain to permit turning. See your John Deere dealer for a chain with a strength rating equal to or greater than the gross weight of the towed machine. Do not use safety chain for towing. DX,CHAIN-19-19930303
Work in Clean Area
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts. DX,CLEAN-19-19900604
Decommissioning — Proper Recycling and Disposal of Fluids and Components
TS1133-UN: Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
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Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. Do not pour waste fluids onto the ground, down a drain, or into any water source. Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN-19-20150601
5R Series Tractors
Safety Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
Avoid Harmful Asbestos Dust
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. DX,DUST-19-19910315
TS220-UN: Asbestos Dust
Use Electronic Display Properly Electronic displays are secondary devices intended to aid the operator in performing field operations, increase comfort and provide entertainment. Displays offer a wide range of functionality, are used in many different machine system applications and can be used with other secondary devices such as handheld electronic devices. A secondary device is any device that is not required to operate your machine for its primary use. The operator is always responsible for safe operation and control of the machine. To prevent injury while operating the machine:
Do not change settings or access any functions that require prolonged use of the display controls while machine is moving. Stop the machine in a safe location and place in park position before attempting such operations. Never set the volume so high that you cannot hear outside traffic and emergency vehicles. To promote safe operation, certain functions of displays may be disabled unless the machine movement is restricted and/or has been placed in the park position. Overriding this safety feature may violate applicable law and can result in damage, serious injury, or death. Only use available display functionality when conditions permit
Position the display according to the installation you to do so safely and in accordance with instructions provided. instructions. Ensure that the device is secured and Always observe safe driving rules, state, or local laws and traffic does not obstruct the driver’s view or interfere with regulations when using any secondary device. the machine operating controls. DX,ELEC,DISPLAY-19-20150113 Do not become distracted by the display. Stay alert. Pay attention to the machine and surrounding environment.
Avoid Hot Exhaust
RG17488-UN: Safety—Hot Parts
Servicing machine or attachments with engine running can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components. Exhaust parts and streams become very hot during operation. Exhaust gases and components reach temperatures hot enough to burn people, ignite, or melt common materials. DX,EXHAUST-19-20090820
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5R Series Tractors
Safety
Clean Exhaust Filter Safely
TS1695-UN: Stop
During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials.
TS227-UN: Fire Safety
Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode. Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning. Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.
TS271-UN: Hand Over Flame
Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures. If service procedure requires engine to be running:
Only engage power-driven parts required by service procedure Ensure that other people are clear of operator station and machine TS1693-UN: Moving Parts
Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station. Shut off engine and remove key (if equipped) before leaving the machine unattended. DX,EXHAUST,FILTER-19-20110112
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