John Deere 5075G 5080G 5085G 5090G 5100G Tractor Workshop Repair Service Manual TM406419 PDF - MJODTM406419.zip
Full Service Repair Manual covering John Deere 5075G (F, L, N, V), 5080G, 5085G (F, L, N, V), 5090G(, H), 5100G(F, N) Tractors (S.N. -00468, -,000469- (Engine F5A) T3A), packed with every piece of workshop data you need to service, fix, and rebuild these machines to a professional mechanic's standard.
The John Deere 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF technical repair manual (workshop edition) contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
tm406419 - John Deere 5080G, 5090G,5090GH,5075GL, 5085GL,5075GF,5085GF, 5100GF,5075GN,5085GN, 5100GN,5075GV,5085GV Tractors Repair (Worldwide Edition) Technical Manual.PDF
tm406428 - Remise en état des tacteurs 5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Édition internationale) French.pdf
tm406429 - Reparatur der Traktoren 5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Weltweite Ausgabe) German.pdf
tm406439 - Riparazione dei trattori5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Edizione universale) Italian.pdf
tm406454 - Reparação de Tratores5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Edição Mundial) Portuguese.pdf
Total Pages: 1,382 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English German etc
MAIN SECTIONS (5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF, 5075GN, 5085GN, 5100GN, 5075GV, 5085GV)
Foreword
Safety
Safety Measures
General Information
Specifications
Tune-Up
Predelivery Inspection
Engine
Removal and Installation of Engine Components
Fuel and Air Intake Systems
Speed Control Linkage
Fuel System
Air Intake System
Electrical System
Battery, Starter Motor, and Alternator
Switches and Sensors
Drive Train (without Transmission)
Component Removal and Installation
Front-Wheel Drive Clutch - Transmission
Differential
Final Drives
Power Take-Off
Transmission Housing - Sensors
Mechanical Transmissions
Removal and Installation of Power Train Components
Clutch
Hi-Lo Clutch (24/24-Speed Transmission)
Transmission
Power Reverser Transmission (24-12)
Removal and Installation of Components - 24/12-Speed Transmission
Electro-Hydraulic Forward High/Low and Reverse Clutch - 24/12-Speed Transmission
Steering and Brake Systems
Steering System
Brake System
Hydraulic System
Hydraulic Pump and Filter
Hitch
Three-Point Hitch
Selective Control Valves
Miscellaneous
Removal and Installation of Components
Front Axle
Front and Rear Wheels
Trailer Mounting and Swinging Drawbar
Fenders
Operator`s Cab and Open Operator`s Station
Remove and Install Operator`s Cab/Open Operator`s Station
Controls and Instruments
Air-Conditioning System
Heating System
Operator`s Cab
Open Operator`s Station
Operator`s Seat
Special Tools
Special Tools (Dealer-Fabricated)
Special Tools (Available as Spare Parts)
TABLE OF CONTENTS................1
Section 05: Safety................23
Group 05: Safety Measures................23
Recognize Safety Information................25
Understand Signal Words................26
“Important” - Information................27
”Note” Information................28
Follow Safety Instructions................29
Handle Fluids Safely—Avoid Fires................30
Prevent Battery Explosions................31
Prepare for Emergencies................32
Prevent Acid Burns................33
Service Cooling System Safely................35
Avoid High-Pressure Fluids................36
Park Machine Safely................37
Support Machine Properly................38
Wear Protective Clothing................39
Work in Clean Area................40
Service Machines Safely................41
Work In Ventilated Area................42
Illuminate Work Area Safely................43
Replace Safety Signs................44
Use Proper Lifting Equipment................45
Keep ROPS Installed Properly................46
Service Tires Safely................47
Avoid Harmful Asbestos Dust................48
Avoid Heating Near Pressurized Fluid Lines................49
Remove Paint Before Welding or Heating................50
Use Proper Tools................51
Dispose of Waste Properly................52
Use Safety Lights and Devices................53
Practice Safe Maintenance................54
Service Front-Wheel Drive Tractor Safely................55
Live With Safety................56
Section 10: General Information................57
Group 05: Specifications................1228
Summary of References - Specifications................1228
Engine................64
Transmission................66
Front-Wheel Drive Clutch................67
Hydraulic System................68
Electrical System................69
Capacities................70
Sound Level................71
Fuel System................72
Brakes................73
Three-Point Hitch................74
Loads and Weights................75
Towable Loads................76
Shipping Weights................77
Maximum Permissible Axle Loads and Total Weights................79
Load Capacity of Tires................81
Load Capacity of Tires With Front Loader................93
Observe Rear Wheel Tread Width Limitations................94
Metric Bolt and Screw Torque Values................97
Unified Inch Bolt and Screw Torque Values................99
Diesel Fuel................102
Handling and Storing Diesel Fuel................103
Do Not Use Galvanized Containers................104
Fill Fuel Tank................105
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III................107
Diesel Engine Oil — Tier 2 and Stage II................109
Transmission and Hydraulic Oil................111
Front-Wheel Drive Axle and Rear Drop Axle Oil................112
Grease................113
Oil Filters................114
Lubricant Storage................115
Mixing of Lubricants................116
Diesel Engine Coolant................117
Operating in Warm Temperature Climates................118
Alternative and Synthetic Lubricants................119
Serial Number Plates................120
Product Identification Number Location................121
Engine Serial Number................122
Fuel Injection Pump Serial Number Location................124
Power Steering Valve Serial Number Location................125
Air-Conditioning Compressor Serial Number Location................126
Transmission Serial Number Location................127
Front Axle (2WD) Serial Number Location................128
Front-Wheel Drive Serial Number................129
Group 10: Tune-Up................58
Summary of References - Tune-Up................131
Using High-Pressure Washers................132
Preliminary engine test................133
Clean Radiator and Oil Cooler................134
Clean Air-Conditioning System Condenser................136
Check Hoses and Hose Clamps................138
Clean Engine Crankcase Vent Tube................140
Clean the Dust Unloading Valve................141
Engine Air Filter................142
Cleaning the Primary Filter Element................144
Cleaning a Dusty Element................145
Secondary (Safety) Element................146
Clean Cab Air Filters................147
Check Belt Wear and Tension................337
Check Engine Oil Level................149
Check Brake System Oil Level................150
Check Coolant Level................152
Check Transmission/Hydraulic System Oil Level................153
Check the Fuel Filter................154
Bleed Fuel System................293
Starting Motor................160
Battery - Checking Specific Gravity................161
Check Neutral Start System................162
Check Setting of Head Lights and Work Lights................164
Check Lights................165
Final Engine Check................166
Tractor Operation Check................167
Group 15: Predelivery Inspection................169
Predelivery Inspection................169
Section 20: Engine................170
Group 00: Removal and Installation of Engine Components................170
Summary of References - Remove and Install Engine Components................172
Engine Repair................173
Specifications................1228
Remove Engine................175
Install Engine................188
Water Pump Repair................199
Remove and Inspect Radiator................200
Remove and Inspect Radiator (5G Remove and Inspect Radiator (5G & 5GH){pgNO}170 5GH)................201
Remove and Inspect Radiator (5GL)................212
Remove and Inspect Radiator (5GV, 5GN Remove and Inspect Radiator (5GV, 5GN & 5GF){pgNO}170 5GF)................218
Install Radiator................228
Remove Oil Cooler................229
Replace Thermostat................231
Remove engine side panels................233
Install engine side panels................236
Vertical Exhaust Pipe Disassembly................237
Horizontal Exhaust Pipe Disassembly................240
Remove Muffler Cover................241
Separate Engine from Front Support................243
Section 30: Fuel and Air Intake Systems................245
Group 05: Speed Control Linkage................245
Summary of References - Speed Control Linkage................247
Adjust Hand Throttle Lever and Accelerator Pedal................248
Recondition Hand Throttle Lever and Accelerator Pedal................257
Group 10: Fuel System................72
Fuel System - Summary of References................260
Injection Pump, Nozzle and Governor Repair................261
Drain Fuel Tank................262
Remove, Inspect and Install Fuel Tank................263
Remove, Inspect and Install Fuel Tank (5G Remove, Inspect and Install Fuel Tank (5G & 5GH){pgNO}245 5GH)................264
Remove, Inspect and Install Fuel Tank (5GL)................270
Remove, Inspect, and Install Fuel Tank (5GV, 5GN, 5GF)................274
Remove, Inspect, and Install Additional Fuel Tank (5GV, 5GN, 5GF)................280
Remove, Inspect and Install Fuel Tank Protection................285
Replace Fuel Filter................287
Replace Fuel Filter (5G Replace Fuel Filter (5G & 5GH){pgNO}245 5GH)................288
Replace Fuel Filter (5GL, 5GV, 5GN Replace Fuel Filter (5GL, 5GV, 5GN & 5GF){pgNO}245 5GF)................290
Replace Fuel Transfer Pump................292
Bleed Fuel System................293
Group 15: Air Intake System................245
Summary of References - Air Intake System................297
Turbocharger Repair................298
Remove and Install the Air Cleaner Element................299
Remove and Install the Air Cleaner Element (5G Remove and Install the Air Cleaner Element (5G & 5GH){pgNO}245 5GH)................300
Remove and Install the Air Cleaner Element (5GL)................301
Remove and Install the Air Cleaner Element (5GV, 5GN Remove and Install the Air Cleaner Element (5GV, 5GN & 5GF){pgNO}245 5GF)................302
Remove and Install Air Intake Hoses................305
Remove and Install Air Intake Hoses (5G Remove and Install Air Intake Hoses (5G & 5GH){pgNO}245 5GH)................306
Remove and Install Air Intake Hoses (5GL, 5GV, 5GN Remove and Install Air Intake Hoses (5GL, 5GV, 5GN & 5GF){pgNO}245 5GF)................311
Section 40: Electrical System................314
Group 05: Battery, Starter Motor, and Alternator................314
Battery, Starter Motor and Alternator - Summary of References................317
Starting Motor Repair................318
Disconnect Battery................319
Connect Battery................320
Remove Battery................321
Install Battery................322
Remove and Install Battery (5G Remove and Install Battery (5G & 5GH){pgNO}314 5GH)................323
Remove and Install Battery (5GL)................325
Remove and Install Battery (5GV, 5GN Remove and Install Battery (5GV, 5GN & 5GF){pgNO}314 5GF)................327
Remove and Install Starter Motor................330
Alternator/Regulator Repair................332
Replace Alternator/Regulator................333
Check Belt Wear and Tension................337
Group 10: Switches and Sensors................314
Summary of References - Switches and Sensors................341
Replace Air Filter Restriction Switch B02................342
Replace Fuel Level Sensor B03................343
Replace Engine Oil Pressure Switch B04................347
Replace Park Brake Switch B05................348
Replace Transmission Speed Sensor B06................350
Replace PTO Speed Selection Switch B07/A................352
Replace PTO Speed Selection Switch B07/B................354
Replace PTO Safety Switch B08................356
Replace Air-Conditioning Pressure Switch B15................358
Replace Neutral Start Switch B36................359
Replace Coolant Temperature Sensor B56................360
Replace Brake Oil Level Sensor B69................361
Replace Engine Speed Sensor B72................362
Replace Brake Pedal Switches B112................363
Replace Thermostat B150................364
Replace Resistor B151................365
Replace Position Sensor B200 (EHS II)................366
Replace Draft Sensor B201 (EHS II)................367
Replace Pressostat B304................368
Replace Main Switch S01................369
Replace Light/Horn Switch S09................371
Replace PTO Mode Switch S21/A (Independent PTO)................374
Replace PTO Mode Switch S21/B (Ground Drive PTO)................375
Replace Hazard Warning Light Switch S106................376
Replace Raise Limit Switch S200 (EHS II)................378
Replace Fuel Shut-Off Solenoid Valve Y13................379
Replace Dashboard................380
Replace Instrument Panel................383
Remove and Install Dashboard Cowls................384
Section 50A: Drive Train (without Transmission)................393
Group 00: Component Removal and Installation................393
Drive Systems - Component Removal and Installation, Summary of References................396
Specifications................1228
Remove and Install Front-Wheel Drive Clutch................398
Remove and Install Differential Assembly................400
Remove and Install Final Drive Assembly................403
Remove Rear PTO Cover................407
Install Rear PTO Cover................409
Group 15: Front-Wheel Drive Clutch - Transmission................66
Summary of References - Front-Wheel Drive Clutch................413
Specifications................1228
Disassemble and Inspect Front-Wheel Drive Clutch................415
Front-Wheel Drive Clutch Cross Section................422
Assemble Front-Wheel Drive Clutch................424
Group 20: Differential................393
Summary of References - Differential................434
Essential Tools................936
Service Equipment and Tools................436