John Deere Tractors 5101E Service Manual (TM112719)
DOWNLOAD SERVICE MANUAL
John Deere Agriculture
5083EN, 5093EN, and 5101EN Tractors Repair (October 2012)
REPAIR MANUAL
PIN pre x LV - USA models 5083E, 5083EN, 5093E, 5093EN, 5101E, 5101EN
TM112719, January 2013
Table of contents
FOREWORD
Section 10 - GENERAL INFORMATION
Group 05 - Safety
Group 10 - General Speci cations
Group 20 - Fuel and Lubricants
Group 25 - Serial Number Locations
Group 30 - Features and Accessories
Section 20 - ENGINE REPAIR
Group 05 - Engine
Group 10 - Cooling System
Section 30 - FUEL AND AIR REPAIR
Group 05 - Fuel System
Group 10 - Air Intake System
Group 15 - Speed Control Linkage
Section 40 - ELECTRICAL REPAIR
Group 05 - Battery, Starter and Alternator
Group 10 - Electrical System Components
Group 15 - Wiring Harness
Section 50 - POWER TRAIN REPAIR
Group 05 - Clutch Housing
Group 10 - Clutch Assembly PowrReverser Transmission
Group 11 - PowrReverser
Group 15 - PowrReverser Transmission
Group 20 - Creeper Assembly
Section 56 - DRIVE SYSTEM
Group 05 - Di erential
Group 10 - Mechanical Front Wheel Drive
Group 15 - Rear PTO Drive Shaft
Group 20 - Final Drives
Section 60 - STEERING AND BRAKE REPAIR
Group 05 - Steering Repair
Group 10 - Brake Repair
Section 70 - HYDRAULIC REPAIR
Group 05 - Hydraulic Pump and Filter
Group 06 - Hydraulic Oil Cooler
Group 10 - Rockshaft
Group 15 - Selective Control Valve
Group 20 - Hydraulic Mid-Mount Control Valve
Section 80 - MISCELLANEOUS REPAIR
Group 05 - Front Axle 2WD
Group 10 - Wheels
Group 15 - 3-Point Hitch
Group 20 - Fenders
Group 25 - Hood
Section 90 - OPERATOR STATION REPAIR
Group 05 - Seat and Support
Group 06 - Control Console and Panel
Group 10 - ROLL-GARDROLL-GARD is a trademark of Deere & Company.
Group 15 - Rear Bar
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identi ed 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, speci cations, wear tolerances, and torque values.
Technical Manuals are concise guides for speci c 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.
Section 10 - GENERAL INFORMATION
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other re hazards.
Store ammable uids away from re 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.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open ame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies
First Aid Kit
Be prepared if a re starts.
Keep a rst aid kit and re extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and re department near your telephone.
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
Filling batteries in a well-ventilated area. 1. Wearing eye protection and rubber gloves. 2.
Avoiding breathing fumes when electrolyte is added. 3.
Acid Burns
Avoiding spilling or dripping electrolyte. 4. Use proper jump start procedure. 5.
If you spill acid on yourself:
Flush your skin with water. 1. Apply baking soda or lime to help neutralize the acid. 2. Flush your eyes with water for 15 30 minutes. Get medical attention immediately. 3.
If acid is swallowed:
Do not induce vomiting.
1. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
2. Get medical attention immediately.
3.
Service and Operate Chemical Sprayers Safely
Safety
Safety
Chemicals used in agricultural sprayers can be harmful to your health or the environment if not used carefully.
Always follow all label directions for e ective, safe, and legal use of agricultural chemicals.
Reduce risk of exposure and injury:
Wear appropriate personal protective equipment as recommended by the manufacturer. (See Handle agricultural chemicals safely found in the Safety Section.)
Fill, ush, calibrate, and decontaminate sprayer in an area where runo will not reach ponds, lakes or streams, livestock areas, or gardens, or near other people.
Keep children away from the chemicals, chemical solutions, and rinsates.
If spray or chemical concentrate contacts skin, hands, or face, wash immediately with soap and water.
If spray or chemical concentrate gets into eyes, ush immediately with water.
If nozzle clogs or system malfunctions, stop engine and relieve spray pressure from system.
Do not place nozzle tips or other components to the mouth to clear obstructions. Keep spare tips on hand for replacement.
Minimize risk of spray drift.
Use large nozzle tips operated at lower pressures
Do not operate solution delivery system at pressures exceeding 345kPa (3.5 bar) (50 psi).
Do not spray when winds exceed 16 km/h (10 mph).
Do not spray when wind is blowing towards a nearby sensitive crop, garden, or populated area.
Properly dispose of unused chemicals, ushing solution, and empty chemical containers.
Decontaminate equipment used in mixing, transferring, and applying chemicals after use.
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides speci c details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS s on chemical products used with John Deere equipment.)
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically at least once per year for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping uid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure uids.
If an accident occurs, see a doctor immediately. Any uid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.
near pressurized uid lines or other ammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate ame area.
Keep ROPS Installed Properly
Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.
The protection o ered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.
The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for your tractor.
Any alteration of the ROPS must be approved by the manufacturer.
Service Tires Safely
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake uid, lters, and batteries.
Use leakproof containers when draining uids. Do not use food or beverage containers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere. Government regulations may require a certi ed air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
Prevent
Machine Runaway
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.
Handle Starting Fluid Safely
Store Safely
Starting uid is highly ammable.
Keep all sparks and ame away when using it. Keep starting uid away from batteries and cables.
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.
Do not incinerate or puncture a starting uid container.
Service Cooling System Safely
Cooling System
Explosive release of uids from pressurized cooling system can cause serious burns.
Shut o engine. Only remove ller cap when cool enough to touch with bare hands. Slowly loosen cap to rst stop to relieve pressure before removing completely.
Remove Evaporator/Heater Core Housing
-
Crop Guard
Heater Hoses
LEGEND:
A Cap Screw (3 used)
B Left-Side Crop Guard
C Heater Hose (2 used)
D Hose Clamp (2 used)
Recover/recycle air conditioning refrigerant. (See Recover/Recycle Air Conditioning Refrigerant in Section 90, Group 25.)
[2] -
CAUTION:
Explosive release of uids from pressurized cooling system can cause serious burns.
Shut o engine. Remove radiator ller cap only when cool enough to touch with bare hands. Slowly loosen cap to rst stop to relieve pressure before removing cap completely.
Remove radiator cap to relieve pressure in cooling system.
[3] - Disconnect battery, negative ( ) cable rst.
[4] - Remove cap screws (A) and left-side crop guard (B).
[5] -
NOTE:
Clamp or crimp heater hoses before disconnecting from cab to prevent draining coolant from engine and radiator.
Tag or label heater hoses to aid during connection.
Ensure heater control knob is in the open or ON position. Loosen hose clamps (D) and disconnect heater hoses (C). Drain coolant from heater core in cab roof. Tag hoses for identi cation.
[6] - Remove outer cab roof. (See Remove and Install Cab Outer Roof in Section 90, Group 15.)
[7] -
NOTE:
Right side window removed for illustration purposes only.
Dome light switch will remain with cover (C) when cover is removed.
Evaporator Drain Tube
LEGEND:
A Screw (2 used)
B Screw
C Evaporator Drain Tube Cover
D Evaporator Drain Tube
Remove screws (A and B).
Right Side Shown
[8] - Remove cover (C) to access evaporator drain tube.
[9] - Disconnect evaporator drain tube (D). Repeat for opposite side of cab.
[10]Right Side Shown
LEGEND:
A Nut (2 used)
B Flat Washer (4 used)
C Screw (2 used)
D HVAC Intake Duct
Remove nuts (A), washers (B), and screws (C).
[11] - Remove HVAC intake duct (D). Repeat for opposite side of cab.
[12] -
Air Conditioning Tubes
LEGEND:
A Air Conditioning Tubes
Pull insulating sleeve covering large air conditioning tube away from tting.
[13]NOTE:
Close air conditioning tubing with caps or plugs to prevent contamination.
Disconnect air conditioning tubes (A) at right-hand corner of evaporator/heater core housing.
[14]NOTE:
Close heater hoses and tubes with caps or plugs to prevent contamination. Tag or label hoses to aid during installation.
LEGEND:
A Main Cab Harness Connector
B Heater Hose
C Heater Hose
Disconnect heater hoses (B and C).
[15] - Disconnect main cab wiring harness connector (A).
[16] -
Cab Roof Main Harness Connector
Housing Bracket Removal
Install Evaporator/Heater Core Housing
[1] -
Housing Brackets
LEGEND:
A Nuts
B Washers
C Housing Bracket
Install evaporator/heater core housing.
[2] - Install washers (B) and nuts (A) on right- and left-hand housing brackets (C).
[3] -
Install Evaporator/Heater Core
[1] -
Evaporator/Heater Core
LEGEND:
A Air Conditioning Tubes
B Allen Screw
C Expansion Valve
D Temperature Sensing Tube
E Evaporator/Heater Core
Check condenser tray (directly under evaporator/heater core) to make sure drain outlets are not plugged.
[2] - Flush evaporator core if evaporator was air tested.
[3] - If evaporator was completely ushed or replaced with a new unit, and no major system leaks were found, add 60 mL (2.0 oz) of refrigerant oil before installation. If leaks are found in the system, check refrigerant oil charge. (See Determine Correct Refrigerant Oil Charge in Section 90, Group 25.)
[4] -
NOTE:
Install new O-rings at all air conditioning connections during assembly. Used or damaged O-rings will leak.
Attach the expansion valve (C) to the evaporator/heater core (E) and install the evaporator/heater core in the housing.
[5] - Connect air conditioning tubes to expansion valve (C) and install clamping plate with allen screw (B).
[6] - Connect air conditioning tubes (A).
[7] - Place temperature sensing tube (D) back into the evaporator/heater core.
[8] -
Inlet and Outlet Hoses LEGEND:
Inlet Hose
Outlet Hose
Connect inlet hose (A) and outlet hose (B) to heater core tubes.
[9] - Connect heater hoses at left cab post and install crop guard.
[10] - Start engine and run heating system to check for leaks. Add coolant to radiator as necessary.
[11] - Install housing cover and secure with seven screws.
[12] - Install cab air lter assembly, tighten knobs.
[13] - Install outer cab roof. (See Remove and Install Cab Outer Roof in Section 90, Group 20.)
[14] - Connect battery, negative ( ) cable rst.
[15] - Purge, evacuate, and charge air conditioning system. (See Flush Air Conditioning System, Evacuate Air Conditioning System and Charge Air Conditioning System in Section 90, Group 25.)
Service Expansion Valve
[1]NOTE: The expansion valve is assembled to the evaporator/heater core prior to installation and is removed as a unit from the HVAC box.
Remove expansion valve. (See Remove Evaporator/Heater Core in Section 90, Group 25.)
Expansion Valve Bench Test
Valve Bench Test Diagram
LEGEND:
Tee (JT03191)
D Hose (JT02109)
E Tube (JT02105)
F Expansion Valve
G Hose (JT02108)
H Regulator Inlet (#218887)
I Tube (JT02103)
J Tube (JT02105)
K Cap (JT03194)
L Plate (R115927/JT02123)
M Screw (AT127259/JT02125)
N Tube (JT02109)
O Elbow (JT05483)
P Ori ce Cap (JT02111)
Q Plate (L77942/JT02124)
R Screw (M67175/JT02126)
S Air Inlet Tee Assembly (JT02112)
T Power Head
Connect expansion valve (F) to regulator (A) that is capable of 820 kPa (8.2 bar) (120 psi).
Install tee (B) with 0.020 in. ori ce cap (C) at regulator outlet.
Connect blue hose (D) between tee (B) and tube (E) on inlet side of expansion valve (F).
Connect red hose (G) between elbow of regulator inlet (H) and tube (I) of expansion valve inlet.
Install tube (J) with cap (without ori ce) (K) on expansion valve outlet. Secure tubes with plate (L) and screws (M).
Install tube (N) with 90° elbow (O) and ori ce cap (P) on expansion valve outlet. Secure tubes with plate (Q) and screw (R).
NOTE:
Both ori ce caps used must have a 0.020 in. ori ce. Any other size will provide false results.
[2] - Fill container with ice water.
[3] - Attach regulator assembly to air inlet tee assembly (S) of 620 kPa (6.2 bar) (90 psi) minimum.
[4] - Adjust regulator until air owing from outlet side of expansion valve (F) is shut o . Air should stop owing at 520 590 kPa (5.2 5.9 bar) (75 85 psi).
Refrigerant Oil Information
CAUTION:
New compressors are charged with a mixture of nitrogen, R134a Refrigerant, and TY22025 (R134a) Refrigerant Oil. Wear safety goggles and discharge compressor slowly to avoid possible injury.
Number Name Use
TY15949 (us) Refrigerant R134a Charges the air conditioning system.
TY22025 (us) R134a Refrigerant Oil
Used to lubricate O-rings, gaskets, and lip seal during assembly of compressor.
New compressors contain 230 245 mL (7.7 8.2 oz) of new oil. The oil level visible through the suction port is normally below the drive shaft. The amount of trapped oil is 81 mL (2.7 oz). Approximately 60 mL (2.0 oz) will seep into the cylinders during shipping and storage.
Typically, 21 mL (0.7 oz) of oil covers internal surfaces of the compressor exposed to refrigerant gas and cannot be drained.
The oil level will be above the drive shaft when 245 mL (8.2 oz) is put in a dry compressor.
The normal operating oil level of a compressor is 30 45 mL (1.0 1.5 oz) and cannot be seen through the suction port.
Evacuate Air Conditioning System
[1]IMPORTANT:
Use only R134a refrigerant recovery, recycling, and charging stations. Do not mix R134a equipment, refrigerant, and refrigerant oils with other refrigerant systems to prevent compressor damage.
LEGEND:
A Discharge Fitting (High-Side) B Suction Fitting (Low-Side)
Tier 2
Tier 3
Group 30 - Heating System
Remove Heater Control Valve
Heater Control Knob
Heater Control Valve
LEGEND:
A Inlet Hose
B Outlet Hose
C Screw
D Heater Control Valve
Disconnect inlet hose (A) and outlet hose (B).
[8] - Remove screw (C) and heater control valve (D).
Leak Test Heater Control Valve
[1] - Connect water pressure hose to control valve inlet and turn the valve arm to closed position.
[2] - Turn water pressure on and check for leakage from the valve outlet.
[3] -
Install Heater Control Valve
[1]Heater Control Valve
LEGEND:
A Inlet Hose
B Outlet Hose
C Screw
D Heater Control Valve
Inspect heater hoses and replace as necessary.
[2] - Install heater control valve (D) and screw (C). Connect hoses (A and B).
[3] - Connect coolant hoses at left front cab post.
[4] - Adjust coolant level. Start engine and run heating system to check for leaks.
[5] -
Heater Control Valve Knob
Install Evaporator/Heater Core Housing Cover
LEGEND:
A Heater Control Valve Knob
B Screw (7 used)
Install evaporator/heater core housing cover with screws (B).
Group 05 - Dealer Fabricated Tools
DFLV1A Final Drive Turning Tool
DFLV1A-Final Drive Turning Tool
LEGEND: A Rod B Cap Screw
Use: Tool is used to rotate nal drive housing to determine rolling drag torque.
Material Required:
40 x 10 x 380 mm (1.575 x 0.394 x 14.961 in.) Flat Steel Stock
12 x 50 mm long (0.472 x 1.969 in. long) Round Steel Stock (2 used)
M8 x 15 mm Cap Screw
Drill two 12 mm (0.472 in.) and one 9 mm (0.354 in.) holes as shown
DFRW20 Compressor Holding Fixture
Holding Fixture
LEGEND:
A 102 mm (4 in.)
B 76 mm (3 in.)
C 70 mm (2.75 in.)
D 6.4 mm (0.25 in.)
E 19 mm (0.75 in.)
F 152 mm (6 in.)
G 254 mm (10 in.)
H 114 mm (4.5 in.)
I 12.7 mm (0.5 in.) x 178 mm (7 in.) Threaded Rod
J Weld
K 12.7 mm (0.5 in.) Hole (2 used)
Use: Tool is used to hold air conditioner compressor during disassembly and assembly.
Material Required:
2 Steel Plates (4 x 2.27 in.) and (10 x 6 in.)
2 Threaded Steel Rods (0.5 x 7 in.)
4 Matching Lock Washers and Nuts
2 Eye Bolts (6 x 1/4 in.)
DFT1162 Snap Ring Removal Tool
2 Matching Washers and Nuts
Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete manual
NOTE:
If there is no response to click on the link above, please download the PDF document first, and then click on it.
