TM134319 - JOHN DEERE 5085M, 5100M, 5100MH, 5100ML (FT4) TRACTOR REPAIR MANUAL PDF DOWNLOAD

5085M, 5100M, 5100MH, 5100ML, 5115M, & 5115ML Tractors (FT4) Repair

REPAIR TECHNICAL MANUAL 5085M, 5100M, 5100MH, 5115M, 5100ML, 5115ML (S.N. MY2014-, MY2014-Dec-2014, MY2016-) TM134319 16FEB16 (ENGLISH)

For complete service information also see: 5085M, 5100M, 5100MH, 5100ML, 5115M, & 5115ML Tractors (FT4) Diagnostic

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TM134319-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Specifications Group 15 - Fuels and Lubricants Group 20 - Serial Number Locations Section 20 - ENGINE Group 05 - Engine Group 10 - Cooling System Section 30 - FUEL, AIR INTAKE, EXHAUST, AND COOLING Group 05 - Fuel System Group 15 - Air Intake System Group 20 - Exhaust System Section 40 - ELECTRICAL Group 05 - Battery, Starter and Alternator Group 10 - Electrical System Components Group 15 - Wiring Harnesses Section 50 - DRIVE SYSTEMS AND TRANSMISSIONS Group 05 - Separation Group 10 - SS Transmission Group 15 - PR Transmission Group 20 - PR Plus Transmission Group 25 - Clutch Assembly—SS Transmission Group 30 - Clutch Assembly—PR Transmission Group 35 - Clutch Assembly—PR Plus Transmission Group 40 - Differential Group 45 - Control Valve Group 50 - Final Drives Group 55 - Hi-Crop Final Drives Group 60 - Rear PTO Drive Shaft Group 65 - Mechanical Front-Wheel Drive Group 70 - Creeper Assembly Section 60 - STEERING AND BRAKES Group 05 - Steering Repair Group 10 - Brake Repair Section 70 - HYDRAULICS Group 05 - Hydraulic Pump and Filter Group 10 - Hydraulic Oil Cooler Group 15 - Hitch Valve Group 20 - Hydraulic Rear Selective Control Valve Group 25 - Hydraulic Mid-Mount Selective Control Valve Group 30 - Hydraulic Lines Group 40 - Front Hitch Section 80 - MISCELLANEOUS Group 05 - Front Axle—2WD Group 10 - 3-Point Hitch Group 15 - Fenders Group 20 - Hood Group 25 - Step Assembly Group 30 - Wheels Group 35 - SCR Covers and Shields Section 90 - CAB/OPEN OPERATOR’S STATION <- Go to Global Table of contents

TM134319-REPAIR TECHNICAL MANUAL

TM134319-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Group 05 - Seat and Support Group 10 - Control Console Group 15 - Roll-Gard Group 20 - Cab Components Group 25 - Open Operator Station Components Group 30 - Air Conditioning System Group 35 - Heating System Section 99 - SPECIAL TOOLS Group 05 - Dealer Fabricated Tools

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TM134319-REPAIR TECHNICAL MANUAL

<- Go to Global Table of contents

TM134319-REPAIR TECHNICAL 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

TM134319-REPAIR TECHNICAL MANUAL

TM134319-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Work In Ventilated Area ........................................................................................................................ 1 Recognize Safety Information ............................................................................................................... 1 Avoid Backover Accidents .................................................................................................................... 1 Prevent Machine Runaway ................................................................................................................... 2 Avoid Contact with Agricultural Chemicals ........................................................................................... 3 Clean Vehicle of Hazardous Pesticides ................................................................................................. 4 Use a Safety Chain ............................................................................................................................... 4 Work in Clean Area ............................................................................................................................... 4 Dispose of Waste Properly .................................................................................................................... 5 Avoid Harmful Asbestos Dust ............................................................................................................... 5 Avoid Hot Exhaust ................................................................................................................................ 6 Clean Exhaust Filter Safely ................................................................................................................... 7 Handle Fuel Safely—Avoid Fires ........................................................................................................... 8 Prepare for Emergencies ...................................................................................................................... 9 Handle Fluids Safely—Avoid Fires ......................................................................................................... 9 Avoid High-Pressure Fluids ................................................................................................................. 10 Install All Guards ................................................................................................................................ 11 Use Proper Lifting Equipment ............................................................................................................. 11 Illuminate Work Area Safely ............................................................................................................... 11 Live With Safety ................................................................................................................................. 12 Service Machines Safely ..................................................................................................................... 12 Support Machine Properly .................................................................................................................. 13 Remove Paint Before Welding or Heating ........................................................................................... 13 Park Machine Safely ........................................................................................................................... 14 Stay Clear of Rotating Drivelines ........................................................................................................ 15 Follow Safety Instructions ................................................................................................................... 16 Use Proper Tools ................................................................................................................................. 16 Service Tires Safely ............................................................................................................................ 18 Keep ROPS Installed Properly ............................................................................................................. 18 Construct Dealer-Made Tools Safely ................................................................................................... 19 Practice Safe Maintenance ................................................................................................................. 20 Understand Signal Words ................................................................................................................... 20 Replace Safety Signs .......................................................................................................................... 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 Specifications ....................................................................................................... 34 Features and Accessories ................................................................................................................... 34 <- Go to Global Table of contents

TM134319-REPAIR TECHNICAL MANUAL

TM134319-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Machine General Specifications .......................................................................................................... 36 Drain and Refill Capacities .................................................................................................................. 37 Service Recommendations for O-Ring Boss Fittings ........................................................................... 38 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 40 Metric Bolt and Screw Torque Values ................................................................................................. 41 Unified Inch Bolt and Screw Torque Values ........................................................................................ 42 Glossary of Terms ............................................................................................................................... 43 Trademarks ........................................................................................................................................ 46 Group 15 - Fuels and Lubricants ......................................................................................................... 47 Alternative and Synthetic Lubricants .................................................................................................. 47 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 48 Operating in Warm Temperature Climates ......................................................................................... 49 John Deere COOL-GARD™ II Coolant Extender ................................................................................... 49 Water Quality for Mixing with Coolant Concentrate ............................................................................ 51 Testing Coolant Freeze Point .............................................................................................................. 52 Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines ............. 53 Disposal of Diesel Exhaust Fluid (DEF) ............................................................................................... 53 Refilling Diesel Exhaust Fluid (DEF) Tank ........................................................................................... 54 Storing Diesel Exhaust Fluid (DEF) ..................................................................................................... 56 Testing Diesel Exhaust Fluid (DEF) ..................................................................................................... 57 Extended Diesel Engine Oil Service Intervals ..................................................................................... 57 Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........................................... 58 Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines ..................................................................................................................................................... 59 John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV ........... 60 Oil Filters ............................................................................................................................................ 60 Fuel Filters .......................................................................................................................................... 60 Diesel Fuel .......................................................................................................................................... 61 Handling and Storing Diesel Fuel ........................................................................................................ 61 Lubricity of Diesel Fuel ....................................................................................................................... 62 Testing Diesel Fuel ............................................................................................................................. 62 BioDiesel Fuel ..................................................................................................................................... 63 Minimizing the Effect of Cold Weather on Diesel Engines ................................................................... 65 Supplemental Diesel Fuel Additives ................................................................................................... 66 Grease ................................................................................................................................................ 66 Mixing of Lubricants ........................................................................................................................... 67 Lubricant Storage ............................................................................................................................... 67 Transmission, Steering, Brake, Hydraulic, and Gear Case Oil ............................................................. 69 Oilscan™ and CoolScan™ ................................................................................................................... 69 Group 20 - Serial Number Locations ................................................................................................... 71 Serial Numbers ................................................................................................................................... 71 Product Identification Number ............................................................................................................ 72 Engine Serial Number ......................................................................................................................... 73 Alternator Identification Number Location .......................................................................................... 73 Power Steering Valve Serial Number Location .................................................................................... 74 Starter Serial Number Location .......................................................................................................... 74 Transmission Serial Number ............................................................................................................... 74 Front Axle (2WD) Serial Number Location .......................................................................................... 74 Mechanical Front Wheel Drive (MFWD) Serial Number Location ......................................................... 75 Air Conditioner Compressor Serial Number Location .......................................................................... 75 Cab Serial Number ............................................................................................................................. 76

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TM134319-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Group 05 - Safety Work In Ventilated Area

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.

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.

Avoid Backover Accidents

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Section 10 page 1

TM134319-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

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.

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.

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Section 10 page 2

TM134319-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

Avoid Contact with Agricultural Chemicals

Harmful Pesticides

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 [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.

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Section 10 page 3

TM134319-REPAIR TECHNICAL MANUAL