5215F/V, 5315F/V, 5515F/V, 5615F/V Tractor (Diagnostics)
TECHNICAL MANUAL 5215F, 5315F, 5615F, 5515F, 5215V, 5315V, 561/V, 5515V TM4861 27JUL10 (ENGLISH)
For complete service information also see: Alternators and Starting Motors
CTM77
00.16, 20.09, 20.09C, 20.11, 20.16, G20.16 and G20.09 Front Wheel Drive Axles
CTM4870
PowerTech 4.5L and 6.8L Diesel Engines Mechanical Fuel Systems
CTM207
PowerTech 2.9L Diesel Engines
CTM125
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage CTM104 IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)
John Deere Agriculture
tm4861-TECHNICAL MANUAL
(g) by Belgreen v2.1
Table of contents FOREWORD EDITION Section 05 - SAFETY Group 05 - Safety Measures Section 10 - GENERAL INFORMATION Group 05 - Specifications Group 10 - Tune-Up Group 15 - Predelivery Inspection Section 20 - ENGINE — REPAIR Group 00 - Remove and Install Engine Components Section 30 - FUEL AND AIR INTAKE SYSTEMS — REPAIR Group 05 - Speed Control Linkage Group 10 - Fuel System Group 15 - Air Intake System Section 40 - ELECTRICAL SYSTEM — REPAIR Group 05 - Battery, Starting Motor and Alternator Group 10 - Switches and Sensors Section 50 - TRANSMISSION — REPAIR Group 00 - Remove and Install Power Train Components Group 05 - Clutch Group 10 - Hi-Lo System (24/24-Speed Transmission) Group 20 - Transmission Section 51 - 24/12-SPEED TRANSMISSION — REPAIR Group 00 - Removal and Installation of 24/12-Speed Transmission Components Group 05 - Clutch - 24/12-Speed Transmission Group 15 - El.-Hydr. High/Low/Reverse Clutch (24/12-Speed Transmission) Section 56 - DRIVE SYSTEMS — REPAIR Group 00 - Remove and Install Components Group 15 - Front-Wheel Drive Clutch — Transmission Group 20 - Differential Group 25 - Final Drives Group 30 - Power Take-Off Group 35 - Housing Sensors Assembly Section 60 - STEERING AND BRAKE SYSTEMS — REPAIR Group 05 - Steering System Group 10 - Brake System Section 70 - HYDRAULIC SYSTEM — REPAIR Group 05 - Hydraulic Pump and Filter Group 10 - Hitch Group 15 - Three-Point Hitch Group 20 - Selective Control Valves Section 80 - MISCELLANEOUS — REPAIR Group 00 - Remove and Install Components Group 10 - Front Axle Group 15 - Front and Rear Wheels Group 20 - Trailer Mounting and Swinging Drawbar Group 25 - Fenders Section 90 - OPERATOR′S CAB AND OPEN OPERATOR′S STATION — REPAIR Group 00 - Remove and Install Operator′s Cab/Open Operator′s Station Group 05 - Controls and Instruments Group 15 - Air-Conditioning System Group 20 - Heating System <- Go to Global Table of contents
tm4861-TECHNICAL MANUAL
tm4861-TECHNICAL MANUAL
(g) by Belgreen v2.1
Group 25 - Operator′s Cab Group 30 - Open Operator′s Station Group 35 - Operator′s Seat and Support Section 211 - DIAGNOSTIC TROUBLE CODES Group EHM - Electro-Hydraulic Management Group EHS - Electronic Hitch Sensing Section 212 - OBSERVABLE SYMPTOMS Group 30 - Fuel and Air Intake System Group 40 - Electrical System Group 50 - Power Train Group 51 - PowrReverser Transmission Group 60 - Steering and Brakes Group 80 - Front-Wheel Drive Section 220 - ENGINE — OPERATION AND TESTS Group 10 - Operational Check-Out Group 15 - Tests and Adjustments Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 240 - ELECTRICAL SYSTEM — OPERATION AND TESTS Group S01 - SE01 - Motor Starting and Charging System Group S02 - SE02 - Instrument Panel Group S03 - SE03 - Horn Group S06 - SE06 - Lighting System Group S07 - SE07 - Work Lights Group S09 - SE09 - Radio, Dome and Console Light Group S10 - SE10 - Fan and Air-Conditioning System Group S11 - SE11 - Wiper and Washer System Group S13 - SE13 - Beacon Light Group S14 - SE14 - Power Outlet Group S15A - SE15A - Electronic Hitch Sensing (EHS) Group S15B - SE15B - Electronic Hitch Sensing (EHS II) Group S16A - SE16A - Hazard Warning and Turn Signal Lights Group S16B - SE16B - PTO System Group S16C - SE16C - Front-Wheel Drive, Differential Lock and Braking System Group S21 - SE21 - Flow Divider Valve Group S26A - SE26A - Electro-Hydraulic Management (EHM) Group S26B - SE26B- Electro-Hydraulic Management (EHM II) Group S27 - SE27 - Electro-Hydraulic Hi-Lo Group 105 - Component Information - Connectors Group 110 - Component Information - Wiring Harnesses Group 115 - Component Information - Electrical Parts Group 120 - Component Information - Ground Connection Group 200 - Wiring Diagrams Section 245 - ELECTRONIC CONTROL UNITS Group 05 - Operation and General Information on Diagnostics Group 10 - EHM-Electrohydraulic Management Group 20 - EHS-Electronic Hitch Sensing Section 250 - POWER TRAIN — OPERATION AND TESTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnostics, Tests and Adjustments Section 251 - 24/12-SPEED TRANSMISSION — OPERATION AND TESTS <- Go to Global Table of contents
tm4861-TECHNICAL MANUAL
tm4861-TECHNICAL MANUAL
(g) by Belgreen v2.1
Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnostics, Tests and Adjustments Section 260 - STEERING AND BRAKE SYSTEMS — OPERATION AND TESTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnostics, Tests and Adjustments Section 270 - HYDRAULIC SYSTEM — OPERATION AND TESTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnostics Group 20 - Tests Group 25 - Adjustments Group 30 - Hydraulic System Schematics Section 280 - MISCELLANEOUS Group 10 - Operational Checks Section 290 - AIR-CONDITIONING SYSTEM — OPERATION AND TESTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnostics, Tests and Adjustments Section 299 - SPECIAL TOOLS Group 05 - Special Tools (Dealer-Fabricated) Group 10 - Special Tools and Test Equipment
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tm4861-TECHNICAL MANUAL
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tm4861-TECHNICAL MANUAL
tm4861-TECHNICAL MANUAL
(g) by Belgreen v2.1
Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
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tm4861-TECHNICAL MANUAL
SAFETY
(g) by Belgreen v2.0
Edition TIR TM4861 01AUG2007
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Section 05 page 1
tm4861-TECHNICAL MANUAL
tm4861-TECHNICAL MANUAL
(g) by Belgreen v2.1
Section 05 - SAFETY Table of contents Group 05 - Safety Measures ................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 ‘Important” - Information ...................................................................................................................... 1 ”Note” Information ............................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 2 Handle Fluids Safely—Avoid Fires ......................................................................................................... 2 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 3 Prevent Acid Burns ............................................................................................................................... 4 Service Cooling System Safely ............................................................................................................. 4 Avoid High-Pressure Fluids ................................................................................................................... 5 Park Machine Safely ............................................................................................................................. 5 Support Machine Properly .................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 7 Service Machines Safely ....................................................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 9 Use Proper Lifting Equipment ............................................................................................................... 9 Keep ROPS Installed Properly ............................................................................................................. 10 Service Tires Safely ............................................................................................................................ 11 Avoid Harmful Asbestos Dust ............................................................................................................. 11 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 13 Remove Paint Before Welding or Heating ........................................................................................... 13 Use Proper Tools ................................................................................................................................. 14 Dispose of Waste Properly .................................................................................................................. 14 Use Safety Lights and Devices ........................................................................................................... 15 Practice Safe Maintenance ................................................................................................................. 16 Service Front-Wheel Drive Tractor Safely ........................................................................................... 16 Live With Safety ................................................................................................................................. 17
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tm4861-TECHNICAL MANUAL
Section 05 - SAFETY
Group 05: Safety Measures
Group 05 - Safety Measures Recognize Safety Information
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.
Understand Signal Words
Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
“Important” - Information Information marked as IMPORTANT points out problems that may lead to machine damage. By following the directions given, these problems can be avoided.
”Note” Information When marked with NOTE, the information given is more detailed or contains restrictions to directions given previously. On the <- Go to Section TOC
Section 05 page 1
tm4861-TECHNICAL MANUAL
Section 05 - SAFETY
Group 05: Safety Measures
other hand, useful information may be given belonging to certain instructions without being directly connected to these directions.
Follow Safety Instructions
Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
Handle Fluids Safely—Avoid Fires
Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
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Section 05 page 2
tm4861-TECHNICAL MANUAL