6105E, 6120E & 6135E TractorsFinal Tier IV (October 2015-) Repair
REPAIR MANUAL 6105E, 6120E, 6135E (S.N. 000001-) TM608619 14SEP15 (ENGLISH)
For complete service information also see: 6105E, 6120E and 6135E Tractors (Final TM608519 Tier IV)(October 2015-) (Diagnostics) Alternators and Starting Motors
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TM608619-REPAIR MANUAL
(g) by Belgreen v2.1
Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Information Group 15 - Fuel and Lubricants Group 20 - Serial Number Locations Section 20 - ENGINE REPAIR Group 05 - Engine Group 10 - Cooling System Section 30 - FUEL, AIR INTAKE, AND EXHAUST SYSTEMS Group 05 - Fuel System Group 10 - Air Intake System Group 15 - Exhaust System Section 40 - ELECTRICAL SYSTEM Group 05 - Charging Circuit Group 10 - Starting Circuit Group 15 - Electrical System Components Group 20 - Wiring Harnesses Section 50 - DRIVE SYSTEMS AND TRANSMISSION Group 00 - Towing Group 05 - Component Removal Group 10 - PTO Group 15 - Clutch Section 60 - STEERING AND BRAKES Group 05 - Steering Repair Group 10 - Front Axle—2WD Group 15 - Front Axle—MFWD Group 20 - Brake Repair Section 70 - HYDRAULICS Group 05 - Hydraulic Pump Group 10 - Hydraulic Oil Cooler Group 15 - Hitch Valve Group 20 - Hydraulic Rear Selective Control Valve Group 25 - Hydraulic Mid-Mount Selective Control Valve Section 80 - MISCELLANEOUS Group 05 - Hood and Fenders Group 10 - Hitch and Drawbar Group 15 - Front Support Section 90 - OPEN OPERATOR STATION REPAIR Group 05 - Seat and Support Group 10 - ROPS Group 15 - Operator Platform Group 20 - Cowl Repair Section 95 - CAB—OPERATOR STATION REPAIR Group 05 - Removal and Installation of Components Group 10 - Air Conditioning System Group 15 - Heating System Group 20 - Seat Section 99 - SPECIAL TOOLS Group 05 - Dealer Fabricated Tools Group 10 - Service Tools <- Go to Global Table of contents
TM608619-REPAIR MANUAL
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TM608619-REPAIR MANUAL
GENERAL INFORMATION
(g) by Belgreen v2.0
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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Section 10 page 1
TM608619-REPAIR MANUAL
TM608619-REPAIR MANUAL
(g) by Belgreen v2.1
Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Replace Safety Signs ............................................................................................................................ 1 Follow Safety Instructions ..................................................................................................................... 2 Work In Ventilated Area ........................................................................................................................ 2 Practice Safe Maintenance ................................................................................................................... 4 Avoid Backover Accidents .................................................................................................................... 4 Prevent Machine Runaway ................................................................................................................... 5 Avoid Contact with Agricultural Chemicals ........................................................................................... 6 Clean Vehicle of Hazardous Pesticides ................................................................................................. 7 Use a Safety Chain ............................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 7 Dispose of Waste Properly .................................................................................................................... 8 Avoid Harmful Asbestos Dust ............................................................................................................... 8 Avoid Hot Exhaust ................................................................................................................................ 9 Clean Exhaust Filter Safely ................................................................................................................. 10 Handle Fuel Safely—Avoid Fires ......................................................................................................... 11 Prepare for Emergencies .................................................................................................................... 12 Handle Fluids Safely—Avoid Fires ....................................................................................................... 12 Avoid High-Pressure Fluids ................................................................................................................. 13 Install All Guards ................................................................................................................................ 14 Use Proper Lifting Equipment ............................................................................................................. 14 Illuminate Work Area Safely ............................................................................................................... 14 Live With Safety ................................................................................................................................. 15 Service Machines Safely ..................................................................................................................... 15 Support Machine Properly .................................................................................................................. 16 Remove Paint Before Welding or Heating ........................................................................................... 16 Park Machine Safely ........................................................................................................................... 17 Stay Clear of Rotating Drivelines ........................................................................................................ 18 Use Proper Tools ................................................................................................................................. 19 Service Tires Safely ............................................................................................................................ 20 Keep ROPS Installed Properly ............................................................................................................. 20 Construct Dealer-Made Tools Safely ................................................................................................... 21 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 22 Wear Protective Clothing .................................................................................................................... 23 Handling Batteries Safely ................................................................................................................... 24 Service Accumulator Systems Safely .................................................................................................. 25 Handle Agricultural Chemicals Safely ................................................................................................. 26 Service Cooling System Safely ........................................................................................................... 27 Use Steps and Handholds Correctly ................................................................................................... 27 Deliver Safely ..................................................................................................................................... 28 Transport Tractor Safely ..................................................................................................................... 29 Servicing Electronic Control Units ....................................................................................................... 29 Welding Near Electronic Control Units ................................................................................................ 31 Keep Electronic Control Unit Connectors Clean .................................................................................. 32 Service Front-Wheel Drive Tractor Safely ........................................................................................... 32 Do Not Open High-Pressure Fuel System ............................................................................................ 33 Group 10 - General Information ........................................................................................................... 34 Sealants and Adhesives Cross-Reference Chart ................................................................................. 34 <- Go to Global Table of contents
TM608619-REPAIR MANUAL
TM608619-REPAIR MANUAL
(g) by Belgreen v2.1
Metric Bolt and Screw Torque Values ................................................................................................. 36 Unified Inch Bolt and Screw Torque Values ........................................................................................ 37 Face Seal Fittings Assembly and Installation—All Pressure Applications ............................................ 38 Metric Face Seal And O-Ring Stud End Fitting Torque Chart—Standard Pressures ............................. 40 Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ................. 41 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures ................................. 42 SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications ..................... 43 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications ................................. 43 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications ............................. 45 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications .................................... 46 External Hexagon Port Plug Torque Chart .......................................................................................... 47 Prevent Hydraulic System Contamination .......................................................................................... 47 Check Oil Lines and Fittings ............................................................................................................... 47 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems ....................................................................................................................................... 48 Identify Zinc-Flake Coated Fasteners ................................................................................................. 49 Use Torque Wrench Adapter ............................................................................................................... 50 Glossary of Terms ............................................................................................................................... 51 Group 15 - Fuel and Lubricants ........................................................................................................... 54 Filling Fuel Tank .................................................................................................................................. 54 Filling Diesel Exhaust Fluid (DEF) Tank ............................................................................................... 55 Alternative and Synthetic Lubricants .................................................................................................. 56 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 57 Operating in Warm Temperature Climates ......................................................................................... 58 John Deere COOL-GARD™ II Coolant Extender ................................................................................... 58 Water Quality for Mixing with Coolant Concentrate ............................................................................ 60 Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines ............. 60 Disposal of Diesel Exhaust Fluid (DEF) ............................................................................................... 61 Refilling Diesel Exhaust Fluid (DEF) Tank ........................................................................................... 62 Storing Diesel Exhaust Fluid (DEF) ..................................................................................................... 64 Testing Diesel Exhaust Fluid (DEF) ..................................................................................................... 65 Testing Coolant Freeze Point .............................................................................................................. 66 Extended Diesel Engine Oil Service Intervals ..................................................................................... 67 Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........................................... 68 Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines ..................................................................................................................................................... 69 John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........... 70 Oil Filters ............................................................................................................................................ 70 Fuel Filters .......................................................................................................................................... 70 Diesel Fuel .......................................................................................................................................... 71 Handling and Storing Diesel Fuel ........................................................................................................ 71 Lubricity of Diesel Fuel ....................................................................................................................... 72 Testing Diesel Fuel ............................................................................................................................. 72 BioDiesel Fuel ..................................................................................................................................... 73 Minimizing the Effect of Cold Weather on Diesel Engines ................................................................... 75 Supplemental Diesel Fuel Additives ................................................................................................... 76 Grease ................................................................................................................................................ 76 Mixing of Lubricants ........................................................................................................................... 77 Lubricant Storage ............................................................................................................................... 77 Transmission, Steering, Brake, Hydraulic, and Gear Case Oil ............................................................. 79 Oilscan™ and CoolScan™ ................................................................................................................... 79 Group 20 - Serial Number Locations ................................................................................................... 81 Serial Numbers ................................................................................................................................... 81 <- Go to Global Table of contents
TM608619-REPAIR MANUAL
TM608619-REPAIR MANUAL
(g) by Belgreen v2.1
Product Identification Number ............................................................................................................ 81 MFWD Axle Serial Number (If Equipped) ............................................................................................ 81 Engine Serial Number ......................................................................................................................... 81 Fuel Injection Pump Serial Number ..................................................................................................... 82 Transaxle Serial Number .................................................................................................................... 82 Cab Serial Number ............................................................................................................................. 84 Selective Control Valve (SCV) Serial Number ..................................................................................... 84
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TM608619-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Safety
Group 05 - Safety 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.
Replace Safety Signs
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Section 10 page 1
TM608619-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Safety
Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Follow Safety Instructions
Follow Safety Instructions Carefully read all safety messages in this instruction. Read the product operators manual for operating instructions and safety messages. Do not let anyone operate without instruction. (A copy of the operators manual may also be available from the Service ADVISOR ™ application.)
Work In Ventilated Area
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Section 10 page 2
TM608619-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Safety
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.
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Section 10 page 3
TM608619-REPAIR MANUAL