John Deere 7515 Tractor Repair Technical Manual TM8132

[Martin Welker]

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John Deere 7515 Tractor Repair Technical Manual TM8132
Size: 17.50 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Tractor
Type of Manual: Repair Technical Manual
Model: John Deere 7515 Tractor
Part Number: TM8132
Publication Date: 2006
Number of Pages: 815 Pages

Contents:
FOREWORD
Section 10 - GENERAL INFORMATION
Group 05 - Specifications
Engine Specifications
PTO
Cooling System
Injection Pump (Lucas)
Air Intake System
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission
Clutch
Creeper Transmission
Hydraulic System
Brakes
Tires
Maximum Weight of Tractor, in kg (lb)
Dimensions
Electrical System
Capacities
Transmission and Hydraulic Oil
Front Wheel Drive Axle Oil
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Hydraulic system inch fitting torques
Hydraulic system metric fitting torques
Product Identification Number
Type Plates
Engine Serial Number
Transmission Serial Number POWRQUAD POWRQUAD is a trademark of Deere & Company
Front-Wheel Drive Serial Number
Differential Serial Number (POWRQUAD POWRQUAD is a trademark of Deere & Company )
Cab Serial Number
Operator’s Platform Serial Number
Sub-Assembly Serial Numbers
Group 10 - Adjusting
Specifications
Using High-Pressure Washers
Preliminary Engine Test
Removing and Cleaning the Primary Air Cleaner Element
Checking the Air Cleaner Safety Element
Installing the Primary Filter Element
Checking for Leaks in Air Intake System Connections
Checking the Crankcase Vent Hose for Clogging
Cleaning Radiator Screen
Checking Expansion Tank Cap
Checking for Leaks in Radiator
Checking Engine Thermostat
Cleaning Water Separator
Checking Fuel Filter
Operating Engine Until It Warms Up and Checking Engine Speed
Checking Fuel Injection Pump Adjustment
Checking Engine Speed Control Link Adjustment
Cleaning Battery, Cables and Battery Box with a Clean Cloth
Checking Neutral Start Circuit
Checking Starter Motor
Checking Lighting Circuit
Final Engine Checks
Tractor Operation Check
Section 20 - ENGINE
Group 00 - Removing and Installing Engine
Special tools
Specifications
Removing Engine
Installing Engine
Section 30 - FUEL SYSTEMS, AIR INTAKE, COOLING AND EXHAUST
Group 05 - Speed Control Link
Hand Throttle Lever and Accelerator Pedal Adjustment
Speed Control Link Adjustment
Hand Throttle Lever—Exploded View
Accelerator Pedal, with Mechanical Speed Control
Accelerator Pedal Adjustment
Group 10 - Fuel System
General Information
Special Tool (Dealer-Fabricated)
Removing Fuel Tank
Installing Fuel Tank
Replacing Fuel Gauge Sensor Unit
Replacing Fuel Transfer Pump
Replacing Fuel Filter
Bleeding Fuel System
Group 15 - Air Intake System
General Information
Air filter - Exploded view
Replacing Air Filter Restriction Sensor
Group 20 - Cooling System
General Information
Specifications
Removing Radiator
Installing Radiator
Replacing Fan
Removing and Installing Expansion Tank
Removing and Installing Thermostat
Filling Cooling System with Coolant
Releasing Drive Belt Tension
Replacing Drive Belt
Replacing Drive Belt Tensioner
Repairing Fan Console
Group 30 - Exhaust System
Exhaust System (Summary of References)
General Information
Specifications
Exhaust to Upper Right-Hand Side
Section 40 - ELECTRICAL SYSTEM
Group 05 - Connectors
Special Tools
General
Using high-pressure washers
Disconnecting electrical circuits
Reconditioning Wire Ends
Installing a Terminal
WEATHER PACK Connectors
METRI PACK connector with rear terminal lock
METRI PACK connector with Front Terminal Lock
METRIC PACK Connectors
CAN BUS Terminating Resistor Connector
Electronic Control Unit Connectors
Connectors
CRIMP SNAP IN Connectors
KOSTAL Connectors
DEUTSCH Connectors
Individual terminals
Fuse and Relay Boxes on Tractors with Operator′s Cab
Fuse and Relay Box on Tractors with Cab and Open Operator Station
Group 10 - Wiring Harnesses
Disconnecting Electrical Circuits
Location of Ground Points
Removing and Installing Wiring Harness W01 — Power Supply
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Open Operator′s Station)
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)
Removing and Installing Wiring Harness W03
Removing and Installing Wiring Harness W04 — Headlights
Removing and Installing Wiring Harness W08 — Open Operator′s Station
Removing and Installing Wiring Harness W09 — Hood (Open Operator′s Station)
Removing and Installing Wiring Harness W19 — Cab Roof
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning
Removing and Installing Wiring Harness W28 — Front End of Transmission (Open Operator′s Station)
Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors)
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Open Operator′s Station)
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)
Removing and Installing Wiring Harness W31 — Power Take-Off for 7-Pin Socket
Work Lights and Turn Signal Lights Harness (Open Operator′s Station)
Windshield Wiper Harness - Rear
Group 15 - Charging Circuit
Charging Circuit (Summary of References)
Special Tools
Specifications
Repairing the Alternator
Disconnecting Electrical Circuits
Removing/Installing Alternator
Removing/Installing Alternator Pulley
Group 20 - Starter Motor Circuit
Starter Motor Circuit (Summary of References)
Specifications
Repairing the Starting Motor
Disconnecting Electrical Circuits
Removing and Installing Starter Motor
Group 25 - Fuses, Relays and Switches
Note
Special Tools
Specifications
Removing Hood Covers
Disconnecting Electrical Circuits
Fuse and Relay Box - Cab Tractors
Fuse and Relay Box - Tractors with Open Operator Station
Replacing Main Fuses
Replacing Starter Motor Relay
Replacing Starter Switch
Replacing Brake Switches
Replacing Light Switch
Replacing Full/Low Beam Switch
Replacing Work Light Switches
Replacing Hazard Warning Light Switch
Replacing Turn Signal Switch
Replacing Horn Switch
Replacing Windshield Wiper and Windshield Washer Switch
Replacing Front-Wheel Drive Switch
Replacing Fan Switch
Replacing Differential Lock Switch
Replacing Rockshaft Remote Control Switch
Group 30 - Monitoring Systems
Note
Note
Disconnecting electrical circuits
Replacing Engine Speed Sensor Unit (B01)
Replacing Engine Oil Pressure Sensor Unit (B04)
Replacing Coolant Temperature Gauge Sensor Unit (B08)
Group 40 - Electrical Components
Note
Special Tools
Specifications
Disconnecting Electrical Circuits
Replacing Socket of 7-Terminal Power Outlet
Replacing Service Socket
Removing Windshield Wiper Motor
Adjusting the Headlights
Adjusting Cab Frame Lights
Lights with Halogen Bulbs
Section 55 - POWRQUAD TRANSMISSION
Group 00 - Removing and Installing PowrQuad Module
Special Tools
Special Tool (Own Fabrication)
Specifications
Separating PowrQuad Housing
Installing PowrQuad Housing
Separating Range Box
Installing Range Box
Final installation
Group 05 - Transmission Selectors Control
Specifications
Reconditioning Gear Shift Mechanism
Reconditioning Range Shift Lever Mechanism
Checking and Adjusting Gear Shift Units
Adjusting Clutch Pedal
Group 10 - PowrQuad Module
Special or Essential Tools
Service Equipment and Tools
Other Material
Specifications
Transmission Components
Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)
Removing and Installing Oil Filter Base
Replacing Oil Filter
Removing and Installing Front Valve Housing
Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)
Removing and Installing Transmission Front Cover
Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)
Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)
Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)
Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)
Removing Transmission Oil Pump
Servicing Transmission Oil Pump
Installing Transmission Oil Pump
Removing Planetary Drive Gears
Repairing Planetary Drive Gears
Installing Planetary Drive Gears
Removing B1 Brake Housing
Repairing Brake B1
Installing B1 Brake Housing
Removing B2-B3 Brake Housing
Reconditioning B1 Brake
Reconditioning B1 Brake
Installing B2-B3 Brake Housing
Removing C4 Clutch
Reconditioning C4 Clutch
Installing C4 Clutch
Removing Reverse Brake
Servicing Reverse Brake
Installing Reverse Brake
Removing Forward Clutch with Planetary Drive (Forward/Reverse)
Servicing Forward Clutch with Planetary Drive (Forward/Reverse)
Installing Forward Clutch with Planetary Drive (Forward/Reverse)
Replacing Output Shaft
Group 15 - Range Box—20 Series
Special Tools
Other Material
Specifications
Repair Information
Preparations
Removing Controls Cover
Removing and Installing Park Ratchet
Shifter — Cross-Sectional View
Removing Shifters and Forks
Installing and Adjusting Forks
Installing Cover
Range Box — Cross-Sectional View
Gear Shift Mechanism — Cross Section
Extracting Main Shaft
Extracting Transmission Shaft
Main Shaft — Exploded View
Transmission Shaft — Exploded View
Gear Shift Mechanism — Exploded View
Park Lock — Exploded View
Repairing Transmission Shaft
Installing Transmission Shaft
Adjusting Axial Play of Transmission Shaft
Installing Main Shaft and Adjusting Position of Pinion
Adjusting Axial Play of Transmission Shaft
Adjusting Gear Shift Mechanism
Repairing and Installing Gear Shift Cover
Final Assembly
Section 56 - DRIVE SYSTEMS
Group 00 - Removing and Installing Component
Special or Essential Tools
Special Tools (Dealer-Fabricated)
Specifications
Removing MFWD Clutch
Installing MFWD Clutch
Removing Differential Housing
Installing Differential Housing
Removing Final Drive
Installing Final Drive
Removing PTO
Installing PTO
Group 05 - U-Jointed Shafts and Torsional Damper
Special Tools
Use of Special Tool KJD10426
Specifications
Removing MFWD Universal-Joint Drive Shaft
Repairing MFWD Universal-Joint Drive Shaft
Installing MFWD Universal-Joint Drive Shaft
Removing Engine Universal-Joint Drive Shaft
Removing Torsional Damper
Replacing Torsional Damper Bearings
Installing Torsional Damper
Installing Engine Universal-Joint Drive Shaft
Group 10 - Front-Wheel Drive Clutch
Special Tools
Specifications
Repair Instructions
MFWD Clutch — Cross-Sectional View
Disassembling MFWD Clutch
Disassembling MFWD Clutch Assembly
Mounting MFWD Clutch Assembly
Mounting MFWD Clutch
Group 15 - Differential
Special Tools
Service Tools
Specifications
Repair Instructions
Removing Differential
Rear Differential — Exploded View
Disassembling Rear Differential
Mounting Rear Differential
Adjusting Differential Pre-Load
Adjusting Play between Differential Teeth
Group 20 - Hydraulic Pump Drive
Special tools
Repair Specifications
Removing and Disassembling Pump Drive Pinion
Removing and Disassembling Pump Drive Gear
Assembling and Installing Pump Drive Gear.
Assembling and Installing Pump Drive Pinion.
Checking and Adjusting Play of Pump Drive Pinion
Group 25 - Final Drives
Special Tools
Service Tools
Specifications
General Repair Procedures — Final Drive
Checking Final Drive Shaft and Retainer
Final Drive — Exploded View
Separating Planetary Carrier
Removing Planetary Carrier
Planetary Carrier — Exploded View
Assembling Planetary Carrier
Cross-Sectional View of Final Drive Housing
Separating Axle Final Drive Housing
Disassembling and Assembling Final Drive Housing
Disassembling and Assembling Axle
Installing Final Drive Housing
Installing Planetary Carrier and Measuring Rolling Drag
Final Assembly
Group 30 - PTO Options
Special Tools
Special Tools (Dealer-Fabricated)
Other Material
Specifications
Replacing PTO Output Shaft Oil Retainer
Replacing O-Ring of Reversible PTO
Removing PTO Clutch
Reconditioning PTO Clutch
Installing PTO Clutch
Reconditioning PTO Brake
Disassembling PTO Transmission
Reconditioning Output Shaft (540/1000 RPM Reversible)
Mounting Output Shaft (540/1000 RPM)
Reconditioning Countershaft (540/1000 RPM)
Mounting PTO Transmission
Adjusting Output Shaft Cone Bearing
Adjusting Countershaft Cone Bearing
Installing Support and Adjusting Cone Bearings
Installing PTO Housing
Removing PTO Modulating Valve
Reconditioning PTO Modulating Valve
Installing PTO Modulating Valve
Repairing Solenoid Valve
Section 60 - STEERING AND BRAKES
Group 05 - Hydrostatic Steering
Special Tools
Specifications
Preliminary Work
Disconnecting/Connecting Steering or Brake Hoses
Steering Valve - Removing
Disassembling Steering Valve
Exploded View of Steering Valve
Mounting Steering Valve
Adjusting Shock Valves
Steering and Steering Column
Reconditioning Steering Column
Steering Valve - Installation
Group 15 - Brake Valve
Special Tools
Specifications
General Repair Procedures — Brake Valve
Brake Valve
Group 20 - Rear Brakes
Specifications
Preliminary Work
Removing Brake Disks
Exploded View of Brake Disks Assembly
Repairing Brake Disks
Installing Brake Disks
Final Assembly
Bleeding the Brakes
Section 70 - HYDRAULIC SYSTEM
Group 05 - Controls
Specifications
Selective Control Valves — Removing and Installing Actuating Elements
Selective Control Valves — Adjusting Bowden Cable
Group 10 - Hydraulic Pump and Charge Pump (PFC Hydraulic System)
Other Material
Specifications
Removing and Installing Charge Pump
Charge Pump Repair
Charge Pump - Checking Lube Oil Valve
Hydraulic Oil Reservoir — Restrictor
Hydraulic Pump — Removing and Installing Pressure-and-Flow Controller
Hydraulic Pump — Reconditioning Pressure-and-Flow Controller
Removing and Installing Hydraulic Pump
Repairing Hydraulic Pump
Group 15 - Valve Block
Special Tools
Special Tools (Dealer Fabricated)
Specifications
Hydraulic System — General Safety and Repair Instructions
Direct Rockshaft Control
Rockshaft Valve (Narrow Version) — Removing and Installing Spacer
Removing Rockshaft Valve
Installing Rockshaft Valve
Repairing Rockshaft Valve
Rockshaft Valve — Depth of Raising and Lowering Valves
Rockshaft Valve — Removing and Installing Stepper Motor
Rockshaft Valve — Removing and Installing Stepper Motor
Rockshaft Valve — Centering Stepper Motor
Removing Priority Valve (PFC Hydraulic System)
Repairing Priority Valve
Installing Priority Valve
Repairing Hydraulic Oil Filter
Group 20 - Rockshaft
Special or Essential Tools
Self-Manufactured Special Tools
Other Material
Specifications
Rockshaft — Removing and Installing of Position Sensor and Toothed Segment
Rockshaft — Removing and Installing Rockshaft
Rockshaft — Removing Rockshaft Cylinders
Rockshaft — Reconditioning Rockshaft Cylinders
Rockshaft — Installing Rockshaft Cylinders
Hitch — Removing and Installing Draft Load Potentiometer and Draft Sensor Shaft
Group 25 - Selective Control Valves and Quick Couplers
Special Tools
Special Tools (Dealer Fabricated)
Other Material
Specifications
Reconditioning Selective Control Valves and Quick Couplers — General Safety and Reconditioning Instructions
Installing Shuttle Valves
Installing Shuttle Valves (Narrow Version)
Removing Selective Control Valves
100 Series Selective Control Valve
Disassembling, Inspecting and Assembling 101 Series Selective Control Valve
Disassembling, Inspecting and Assembling 300 Series Selective Control Valve (SCV)
Installing Selective Control Valves
Adjusting Pressure with Selective Control Valves
Quick Couplers — Service
Mounting Quick Coupler
Section 80 - MISCELLANEOUS
Group 00 - Removing and Installing Components
Special or Essential Tools
Special Tools (Dealer-Fabricated)
Specifications
Removing Main Chassis
Installing Main Chassis
Removing Front-Wheel Drive Axle
Installing Front-Wheel Drive Axle
Group 05 - Main Chassis
Specifications
Reconditioning Main Chassis
Group 15 - Front Wheels, Rear Wheels and Fenders
Special or Essential Tools
Specifications
Installing Front Fenders
Removing Front and Rear Wheels
Reconditioning Front and Rear Wheels
Installing Front and Rear Wheels
Group 20 - Center Link Bracket and Swinging Drawbar
Specifications
Checking Swinging Drawbar Wear
Installing Center Link Bracket
Swinging Drawbar
Adjusting Retention Rod
Section 90 - OPERATOR′S CAB
Group 00 - Removing and Installing Components
Special Tools
Dealer-Manufactured Special Tools
Specifications
Swinging Up Operator′s Cab
Swinging Down Operator′s Cab
Removing Operator′s Cab or Platform
Installing Operator′s Cab or Platform
Checking and Adjusting Gear Shift Units
Group 15 - Air Conditioning System
Special Tools
Specifications
Tightening Torque for Refrigerant Hoses
Safety Regulations
Handling Refrigerant
In the Event of an Emergency
Safety Equipment
Storage of Refrigerant Containers
Refrigerant R134a
Important
Other Material
Specifications
General Information
Filling the Cylinder
Cleaning the Air Conditioning System
Evacuating the System
Adding Oil to the Air Conditioning System
Charging Air Conditioning System
Leak Test
Separating Compressor
Checking Compressor Level
Disassembling Compressor Clutch
Checking Clutch Hub Separation
Installing Compressor
Separating and Installing Condenser
Separating and Installing Drier
Replacing Expansion Valve
Separating and Installing Evaporator and Expansion Valve
Installing Condensation Water Drain Hoses
Layout of Condensation Water Drain Hoses
Separating and Installing Thermostat
Separating and Installing High/Low Pressure Switch
Vacuum Pump — General Information
Group 20 - Heating System
Fan and Heater, Disassembling
Removing Cab Air Filter
Separating and Installing Fan
Separating and Installing Heater Regulator
Separating Heater/Evaporator Housing
Group 25 - Operator′s Cab
Removing Cab Frame
Cab Mounting Torques
Removing and Installing Windshield
Removing and Installing Rear Window
Installing Door Lock
Adjusting Window Contact Pressure
Removing and Installing Operator′s Cab Door
Removing and Installing Sun-Visor Roller
Section 99 - SPECIAL TOOLS (DEALER-FABRICATED)
Group 05 - Special Tools (Dealer-Fabricated)
Suspension Device
Lifting Device
Holding Device
Suspension Eyes for Operator′s Cab
Holding Tool
Wooden Block
DFRW79 - Piston Holding Tool
Socket Wrench Insert
Seal Installer
Driver
Assembly and Guide Mandrels
Turning Device
Bushing
Seal Installer
Socket Wrench Insert
Special Wrench
Quick Coupler Securing Support
Lifting Tool